[Post edited to reflect the many changes that have occurred to the mask design since the project began.]
Sith Acolyte Mask from the trailer "HOPE" for SWTOR.
This is a complete, 100% scratch-build by me: I sculpted the molds; I do all the vacuum forming, casting, painting, etc. What I cannot take credit for is the hard work the design artists at BioWare did to come up with this amazing character concept!
Now on version 4 of the mask.
Mold was completely scratch built, and is unrelated to my mask versions 1-3. Complete build diary can be seen on my website thedrunkenmynock.com
Sith Acolyte V3 (my previous Acolyte mask version: arose from casting one of the earlier V2 masks in resin)
Acolyte V2 (older mask version: made by vacuum forming ABS or HIPS over a modified original Bondo mold in two layers, with the detail pattern cut out from one layer and glued onto another).
Acolyte V1 (the oldest: made by vacuum forming ABS or HIPS over very first Bondo mold in two layers, with the detail patterns cut out from one layer and glued onto another):
Darth Nihilus from Knights of the Old Republic game:
LEFT: official game art - RIGHT, my finished vacuum formed mask
Original Post with production info begins below:
Here is the mold skulpted out of Bondo. I used a resin thinner to thin out Bondo to make it more liquid (to cut down on the amount of sanding).
The second project is a Sith Acolyte mask from Star Wars The Old Republic game (left), which is still in its initial rough stage! This one I will not be able to vacuum form as there will be too many sharp angles and tiny details (which will not come out well, unless I use an exremely thin plastic). I'll keep you posted!