Iron Man Mask Step 1
I drew out all of my contour lines in blue ink on the yellow foam brick before going to the machine shop
Iron Man Mask Step 2
After machining and hand shaping, I got this first mock up of the mask ready
Iron Man Mask Step 3
I built up a clay base for the mask to sit on, so I could vacuum form a plastic mold around the foam model. I also covered the foam in a thin layer of clay to make a nice clean and smooth finish
Iron Man Mask Step 4
After successfully vacuum forming the mask, I took the plastic shell to the machine shop and cleaned up the design a little and reshaped it where needed
Iron Man Mask Step 5
Plastic mold after I sand blasted it for a perfect finish before spray painting
Iron Man Mask Step 6
After applying several coats of paint and sanding to perfection, here is the comparison of the foam model on the bottom (brown) to the finished plastic shell model on the top
Iron Man Mask Completed
