Blue's mask project - Charley Hall
Headcast and sculpt

Headcast and sculpt

I didn't get any photos of it, but the first step in the fabrication was getting my head cast! Moulded in alginate and cast in plaster. This gave me a solid basis to block my mask out on so that when I cast it, it was guaranteed to fit my face.
You don't necessarily need your head cast, you can buy a head to work on - but make sure that it is realistic to human proportions as many wig heads are much smaller than an average face.
Here I start to block out the shape of the mask, to get the form down before I work on any detail. I work in Plastilene, a sulphur-based clay product that doesn't set (similar to plasticine) rather than clay. Plastilene is great to work in if you're moulding and casting but not if you want the sculpt to be the finished product on it's own.