Helmets & Masks
Through our years of cosplay, we’ve created several masks and helmets. Here’s a collection of our build tutorials, ranging from one-off foam builds, to Pepakura, to molding and casting! We’ve also gotten some incredible mask and helmet kits from great makers that we’ll be finishing and painting.
Bill and his good friend Nick Kettman of Modulus Props show you how to make brush-on molds and slush casts of their custom sculpted masks!
Bill and his friend Nick Kettman of Modulus Props show you how to sculpt your own custom mask!
Zortax sent us their M300 3D Printer and a pile of filament to create a project. Our family and cosplay counterparts, Jaimi and Rob, were crafting a Samus costume from the Metroid video games and wanted to 3D print the helmet. What a great way to try out the large build volume of the M300 and make an awesome cosplay helmet!
This is it! The final step in our epic cheap 3D printer helmet build. Follow along as Bill shows how he sanded and painted the Tank Trooper helmet that was printed on the ultra budged Anet A8 3D printer.
Bill was visited in the shop today by Domestic Dan and the duo made a custom built corgi masquerade mask from EVA foam!
While in Los Angeles for VidCon, Bill crashed Evil Ted’s shop to team up with internet superstar Ali Spagnola to build a Marvin the Martian Helmet!
The last step in the epic Star-Lord helmet kit build is to add those iconic glowing eyes. Bill does some Dremel work, soldering, and assembly.
The Star-Lord Helmet kit is nearing completion, so Bill went over the entire thing with oil and acrylic paints to weather it and make it look a little bit dirty.
After reinforcing the Star-Lord helmet with epoxy and fiberglass, Bill got to work doing the bulk of the paint job. For this prop, he went with “metalizer” lacquers and an airbrush.
To complete the foamVoltron Paladin Helmet build, Bill shows how he painted it with acrylic paints and customized a visor.
Bill embarks on an epic Guardians of the Galaxy build as he starts finishing up his WM Armory Star-Lord helmet kit. The casting needed some trimming and clean up work to get it ready for painting and finishing.
Now that Bill has a basic helmet form created, he shows off how to add layers of detail, hiding the seams and creating a finished piece.