eso screenshotThis is the helmet I want to build. I’ll use different colors for it, but the model is the same.


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I cut the patterns out on thick paper and trace the outlines on the craft foam.


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After I cut out the craft foam pieces I trace their outlines to the thermoplastic sheets. I usually cut a 1cm wide edge which will be folded to the other side of the craft foam piece. It saves a lot of material.

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I prepare the upper head piece, heat the thermoplastic base and the press the craft foam on it.

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I recommend to work with all parts step by step. Do not cut your thermoplastic and heat all the pieces already. You better work with it as long as it’s warm and re-heating the thermoplastic can cause lot of bubbles. I try to avoid to re-heat bigger surfaces while working.

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Drawing the details onto the surface where later a few thermoplastic pieces will replace them.

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The gap between those parts gets a filler.

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Placed all the details here with your thermoplastic. Now we move to the next step.

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Preparing the Orc face mask.

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Thermoplastics are flexible when heated so they can be shaped without cracking.
I decided to shape it as close to the original as possible to save some material later.

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I used scraps of thermoplastics which I keep in a box.
They can always be used to sculpt something so don’t throw them away.

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Looks much more like the orc face mask now. But it still needs a bit of detailing.

P1030437 The mask is prepared for the silicone mold. A layer of Apoxie Sculpt will help to get a smooth surface here.

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When the sculpt is done I usually sand down the bumps until the surface  is smooth.
And then cover it with spray primer.

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For the ponytail I bought false brown hair and cut a thick piece.
Tied it down and then burnt one end with the heat gun to glue all strands together.

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Looks messy, but it’s tight and no hairloss is garanteed.

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The ponytail will is wrapped in a piece of thermoplastic/foam, which is attached to the helmet at the back.

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The mask is covered in silicone rubber now.
With this I’ll be able to make as many casts as possible and finally make my own Orc army.

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