Hey guys thought I'd post a thread of my deadpool faceshell and frame combo. Its deffinitely one of the builds I've done that I'm most proud of.
So first off the idea came from customers purchasing numerous variations of my deadpool masks so they could have different expressions, i felt it would save them time having a mask that would allow to have interchangeable expressions and it would save me time sewing additional hoods (i complete hate sewing)
Heres a pic of my old mask.
in then scrapped that idea and teamed up with my bud stevie from crimson coscrafts to render a 3d model that I could print and finish
As you can see the model looks fantastic and I highly recommend working with stevie if you need a model built.
So i finally got the print back
and after some time got it ready for molding
i did a few light rondo coats brushed on with a foam brush so it would fill in the print lines and then i sanded it with 220 grit sandpaper. Now finally able to apply silicone and a mother shell it was time to knock these out
I have started roto casting them but sid cast a fiberglass buck so i could also vacuum form them for better consistency. As far as the eye pieces those were a little trickier to mold but i molded it as a two piece mold so it would be able to best replicate the print.
so now that i had molds it came to to produce some shells. I used Sc65d for the shell and SC onyx fast for the eye pieces 
now that i had my parts now came assembly. I partnered with ken landrum who was working on a pattern for the new deadpool movie and gave his mask pattern a test after some modifications we got a good template and came the (not so) fun task of sewing 
now that i had the hood sewn up and the magnets in the only step left was the eye mesh material. so for this i have used two different materials my preffered material is the white plastic mesh from joanns because it doesn't fog up i spray the back side with black plastidip because it eliminates the glare when looking through. But for the look with more sheen i use .010 PETG and perforated vinyl (most people have trouble finding this my secret is look up places that do window graphics they can print any color or you can get white. The best part is the back side is already black) so now that all the pieces are in place now comes a finished mask. 
I'll post client pictures as they come. But i did mention alternate expressions and those have just been finished and are ready to print the expressions are confused, happy and entense
So first off the idea came from customers purchasing numerous variations of my deadpool masks so they could have different expressions, i felt it would save them time having a mask that would allow to have interchangeable expressions and it would save me time sewing additional hoods (i complete hate sewing)
Heres a pic of my old mask.
in then scrapped that idea and teamed up with my bud stevie from crimson coscrafts to render a 3d model that I could print and finishAs you can see the model looks fantastic and I highly recommend working with stevie if you need a model built.
So i finally got the print back
and after some time got it ready for molding i did a few light rondo coats brushed on with a foam brush so it would fill in the print lines and then i sanded it with 220 grit sandpaper. Now finally able to apply silicone and a mother shell it was time to knock these outI have started roto casting them but sid cast a fiberglass buck so i could also vacuum form them for better consistency. As far as the eye pieces those were a little trickier to mold but i molded it as a two piece mold so it would be able to best replicate the print.
so now that i had molds it came to to produce some shells. I used Sc65d for the shell and SC onyx fast for the eye pieces now that i had my parts now came assembly. I partnered with ken landrum who was working on a pattern for the new deadpool movie and gave his mask pattern a test after some modifications we got a good template and came the (not so) fun task of sewing now that i had the hood sewn up and the magnets in the only step left was the eye mesh material. so for this i have used two different materials my preffered material is the white plastic mesh from joanns because it doesn't fog up i spray the back side with black plastidip because it eliminates the glare when looking through. But for the look with more sheen i use .010 PETG and perforated vinyl (most people have trouble finding this my secret is look up places that do window graphics they can print any color or you can get white. The best part is the back side is already black) so now that all the pieces are in place now comes a finished mask. I'll post client pictures as they come. But i did mention alternate expressions and those have just been finished and are ready to print the expressions are confused, happy and entense
