The process of creating prosthetics

I have started looking into the process of making prosthetic appliances. This is a quick post showing the different steps in making prosthetics.

These are some links I have found useful while learning how to make prosthetics:
http://www.ps-composites.com/blog/HOW-TO-MAKE-PROSTHETICS/

Any of the videos of the next link are amazing at teaching you how to make these appliances:
https://www.youtube.com/results?search_query=how+to+make+prosthetics

Any of the videos of this next link are amazing at showing you how to sculpt different textures and shapes for prosthetics:
https://www.youtube.com/results?search_query=how+to+sculpt+a+prosthetic

Any of the videos on the next link are amazing at showing you how to life cast:
https://www.youtube.com/results?search_query=how+to+life+cast

I find videos easier to understand and learn from than articles and written instructions so that's why I have put links to so many videos.

Life casting:

Life casting involves casting someone's body part depending on where you want the prosthetic to be, this makes a base onto which you can sculpt the prosthetic piece onto. You can life cast with alginate, Although there are other casting materials available. For my recent face cast I used Modroc (plaster bandage), as this method is cheaper than using alginate and I just find it easier to use.

Before starting the life casting make sure Vaseline applied to all areas with hair on them, for example on the face put Vaseline on the eyebrows, the eyelashes, any facial hair and any bits of your hair on your head that wont be covered by cling film. Cling film is the quickest way to block out hair on your head.

When using alginate, it is best to start by putting a pea size bit up each nostril and then squeezing the, out. This ensures that as much of the nose can be cast as possible without covering the nostrils. It is also best if you line where the lips touch together with it as this ensures it picks up the detail and the shape of the lips correctly. It is also important to make sure the water you use in the alginate isn't too cold as this can send he person into shock and make them panic, but you don't want the water to be too hot so the alginate sets super quick. Its always best to make sure your model is always feeling ok while doing the life casting, so simple hand gestures should be in place for them to do to say if they are ok and for when they aren't ok, also keep asking them if they are feeling alright. When the cast is done with alginate it is important to back the cast with modroc to make it stiffer so that you can pour a mixture into it without it bending out of shape or breaking.

Creating the positive cast:

From the life cast you make a positive cast, this is the part that you can actually sculpt onto. This is mainly done with a plaster, a fiberglass or a polyurethane. I do my casts in plaster. Make sure you buy good quality plaster because if you don't it could just fall apart while your sculpting onto it.

Basically all you do is mix the substance, and pour it into the mould and wait for it to dry then when you remove it you have a perfect cast.

Sculpting:

Sculpting is the most fun part of the process because its all about imagination. I personally sculpt with air drying clay. For sculpting it is important to have a range of sculpting tools and sponges. I have a metal set of different sculpting tools, various different textures sponges and I also use toothbrushes and paintbrushes to create texture.

Make sure the edges of the sculpt are smooth and as thin as possible as this helps the final product blend into the skin better.

Making a cast of the sculpt:

Making a cast of the sculpt is the hardest part to explain, but basically you are doing what you did to your life model, to the sculpted piece. You can use a silicone, or alginate but I choose to use plaster that is of a thicker consistency and again back it with modroc. Since wet plaster doesn't stick to dry plaster this works perfectly fine aslong as you use a releasing agent like Vaseline. Another way you can do this is put a wall of clay around the sculpt and pour in plaster. When you take the two pieces apart and remove the clay from the mould, you are left with a positive cast of the face and a negative cast of the sculpted piece. Make sure these two parts are clean before proceeding.

Making the prosthetic:

Prosthetics can be made out of a range of materials from silicones, to gelatine but I prefer to make mine out of latex as it is a cheaper alternative. Latex may not be the best material but it does the job.

When making the prosthetic, pour whatever substance you decide to use into the negative mould of the sculpt. The positive cast of the face should then be placed back into the other half, allowing any excess latex or silicone to come out of the mould. Doing this ensures that the prosthetic actually fits the models face correctly.

Once it is all dry, make sure you carefully separate the two halves, and remove the prosthetic carefully using talc powder to help remove it from the mould.