Face Casting

This semester in special effects we are going to be learning about prosthetic’s, but to  be able to create prosthetic’s we need to create  a face cast to work off. Also in special effects this semester we  have the privilege to be tutored by a member of the Madame Tussauds  casting team. In our fist lesson we were being shown how to create a face cast using Mouldlife Life Form  Face Coat and Modrock. Face  casts can be used in various areas of make up such as film, television and theater. Once the face cast is produced then prosthetic’s can be made and molded to fit an actors face. Below are some pictures of the process along with a method of how we created the face casts.

This slideshow requires JavaScript.

Products used

Mouldlife Life Form Face Coat Part A & B

Modrock (Plaster Bandage)



  1. Mark an out an outline on the face of where you would like the cast to be.
  2. Cove up the model with a plastic sheets and gaffer tape to secure the back to prevent anything falling.
  3. Mix together both A and B parts of Mouldlife Face Coat (Half and Half).
  4. Roll mixture onto the skin taking extra care around the eyes and nostrils (DO NOT cover the nostrils as this allows the model to breathe throughout the process) Apply a good layer all over the face.
  5. Apply gauze on top of the face coat, over the eyes and mouth.
  6. With a bowl of warm water, fold the Modrock in half and put into water and remove any excess water and apply to the face covering the gauze and all the face coat, once you have covered most of the face with Modrock apply a strip around the sides of the face and one down the nose giving the cast more support.
  7. Allow the Modrock to set.
  8. Using a blunt modeling tool, remove the face coat and  Modrock  by getting the tool between the face coat and the skin ( to help with removing the face cast get the model to move their face).

Using Plaster to fill Face Cast

This slideshow requires JavaScript.

Products Used

Powder Plaster




  1. Cover the nose of the Face Cast with a flat piece of clay and fix the face cast to the board with more clay to secure and keep level.
  2. Cover any visible plaster and bandage with Vaseline.
  3. Pour a cup of cold water into a bowl and add a handful of plaster, sieving it into the water using your hands.
  4. Allow plaster to soak into the water before mixing to a single cream texture (when plaster starts to rest on top and looks like thick wet sand then it’s ready to mix).
  5. Use hands to mix plaster and to get rid of lumps.
  6. Brush layers of plaster until no green rubber is showing ( the plaster may repel due to grease from rubber or skin/make-up).
  7. Continue to paint the plaster until a thick layer is applied and allow to dry.
  8. Once the first layer of plaster is dried, spray with some water to help the next layer of plaster adhere.
  9. Paint another layer of plaster and add scrim (fabric) and then add another layer of plaster on top of the scrim be careful not to create any air bubbles.
  10. After the final layer has dried use a blunt tool between the rubber and the plaster and gently remove the face cast and tidy up any scrim that may be hanging over the edge.

Sorry for such a long post, thanks for reading

Hannah xoxo


One thought on “Face Casting

  1. Pingback: Making A Silicone Prosthetic | Hannah Todhunter

Leave a Reply

Fill in your details below or click an icon to log in:

WordPress.com Logo

You are commenting using your WordPress.com account. Log Out / Change )

Twitter picture

You are commenting using your Twitter account. Log Out / Change )

Facebook photo

You are commenting using your Facebook account. Log Out / Change )

Google+ photo

You are commenting using your Google+ account. Log Out / Change )

Connecting to %s