Foam latex, step by step

Now it was time to cast the actors ears.
For this I built a small plastic box that I could glue around his ear and easily cast him using alginate.

Here I am filling the mould with Ultracal 30 and will get a perfect duplicate of his ears in plaster.
I wanted to make a simple mould.
Ear moulds can be extremely complicated due to the fact that ears are nothing but undercuts. I filled the back of it and the ear hole (is there a proper name for it?) with Roma clay as seen on the picture.
After doing this I moulded it with alginate and plaster bandages. The result was an plaster ear almost without undercuts. The only shortcoming of this technique is that the foam piece doesn't fit beautifully behind the ear but in this case the wig will cover this defect so I decided to use this simpler kind of mould anyway. 

Here I have sculpted the tips of ears and the overflow. The round holes are called keys and the use for them is to give the finished mould a good grip to the other half.
Now I am ready to make the mould.
I have built clay walls to make a shape for the negative plaster mould.
To make the separation easier I always spray a little silicon on the sculpture.

I filled the moulds with Ultracal 30 just as I did with the face piece and after 2 hours I pried them apart and it went just fine.
No undercuts at all!
I have now sent the actor to the optician and have ordered lenses. I have ordered  "crazy lenses" for him.
On this picture I have tried them on myself. They come in several different models and cost about $150 a piece. Don't they look great?


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