This tutorial shows how to make a latex Batman mask, cast from a plaster mold. This method can be applied to any mask design. It's not a perfect process, but it is a good budget option, easy for beginners.
Read FAQ below for answers to the most common questions:
How much does this cost?
Estimated cost is about $10 for the mold, and $5 for each mask cast. It's best to buy mask-making latex by the gallon, for about $50. A gallon of latex is enough to make several masks with. Buying the latex, plaster, and clay to start mask making can put you back around $60, most of that being the cost of latex. Probably not the cheapest method for making only a single mask (unless you can find only a half-gallon or pint of latex), but great for multiple projects.
Where can I buy latex?
It's best to buy liquid latex for mask-making on online stores, like eBay, or from other effects product suppliers. These suppliers usually have it in stock:
http://myworld.ebay.com/ecbarista/
http://myworld.ebay.com/fun_fx/
If you can find a local source, that can be cheaper.
MAKE SURE that if you buy latex, it's specifically latex for mask-making. Other more common "molding " latex products are not safe on skin.
Where can I get good, cheap clay?
The clay I used was a water-based pottery clay I bought at Hobby Lobby. A 25-pound box for $10 (with a 40% off coupon). That's a great start, a lot of clay that can last a while. It's soft and easy to work with for beginners. Or most arts and craft stores should have a 10-pound box of cheap modeling clay for under $10.
Why not just buy the costume mask? It looks better than this one...
It depends on your head. Heh. My nose is a bit large, and so my face looked rather goofy on the costume mask This one fits my head better, doesn't have a Velcro seam at the back, and better proportioned overall.
However, getting a perfectly smooth finish on a mask like this is very difficult. That would come down to having a very clean mold, which I didn't have. If you take the time, a homemade mask like this can look better than the costume version.
See how I made a Bane mask and the rest of the Batsuit:
http://www.youtube.com/watch?v=Ctw1j32znSg
See the video I made with this, along with the rest of the costume, here:
http://www.youtube.com/watch?v=YHLbLQf-ado
More detailed instructions and material lists:
http://www.instructables.com/id/Latex-Mask-Part-1-Plaster-Head-Mold-and-Clay-Scul/
http://www.instructables.com/id/Latex-Mask-Part-2-Molding-the-Sculpt-and-Casting-/
Time-lapse of mask sculpt:
https://vimeo.com/41642825
