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Son Character :
Head Casting
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Now that the mould has been made, it is time to cast the head in silicone. Image 01 shows a slight
from a couple of air bubbles in the nostril area, these will be resolved further in this doc
I started positioning the armature roughly where I wanted it, then using some wire I began to add s
sections to the face.
01.02. 03.
Air bubbles in theresin means the nostrils
wont be as deep
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Here there is wire to make the eyebrows and lips move for animation. When I was happy with the w
it from the mould and prepared the first batch of silicone to paint onto the mould
04.
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When the first layer of silicone was painted, I went about fixing the nostril issue. I figured that if I p
cocktail stick in the bubble area of each nostril, I would be able to remove it later on leaving a bigg
By applying the temporary pieces while the silicone was wet, it acted as a mild glue to keep
06.
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After the first coat, I placed the temporary eyes into the socket supports so Id be able to remov
eyeballs later in the process, this means I have sockets to pop the animation eyes into when the he
would be moveable.
08.
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I coated the mould with 3 layers of silicone. While those layers were setting, I constructed the bul
the same upholstery foam as I used on the body.
10. 11.
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While I was constructing the foam core to the head, I added some ear wires incase I wanted to anim
during the animation.
13. 14.12.
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These images show my process in detail.
15. 16.
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Each layer of silicone only takes an hour to cure, so it didnt take long before I was able to test and
and foam to check it was fitting nicely.
17.
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In the piece of neck foam, I cut a little groove as a snug space for the armature to fit
19.
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With the foam and armature just as I wanted, I grabbed the contact adhesive so I could finalise
22.21.
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I glued around the armature to make sure the glue wouldnt interfere with the movable
24. 25.
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This is how the inside of the head looks from the front and both sides.
27.26. 28.
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I check the armature one more time in the mould, then I remove it, pour in some silicone, then plac
into the silicone, squidge it in and pour more silicone over the top of the foam. Also, I pour another
the back of the head.
30.
29.
31.
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The silicone had cured in roughly an hour. These images show how the head looked as I pulled it
41.
35. 37.36.
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I removed the thin layer of silicone that covered the eyeballs. This was so I could pop out the tem
neaten up the seam.
41.
38. 39. 40.
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Image 46 shows a soft brush dipped in talcum powder which I used to brush the inside of the eye so
make the eyes move around easier without the plastic of the eyes sticking to the rubber of the silico
the final eyes and tested the movement using a pin. I also trimmed off all of the excess silicone
process.
46. 47. 49.48.
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I needed access to the screw of the armature in the neck so I cut a small hole where I had left a co
meant I was able to remove the cocktail stick with some fine tweezers and the alan key could acces
50. 51. 52.
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With access to the armature I was able to remove the temporary neck bar and replace it by popping
body and tightening it up.
53.
54.
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56. 57. 58.
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