Orc Facial Prosthetic

This prosthetics project was completed as part of an intensive university "turbo", giving a strict two-week timeframe from start to finish, which helped simulate the fast-paced nature of industry production. The project began with lifecasting, where alginate was applied to capture the form, detail, and texture of the face, supported with a Modroc plaster bandage shell for structure. Once set, the mould was carefully removed and filled with plaster to produce a solid positive life cast, which was then demoulded and used as the base for sculpting. I developed a clay sculpt directly onto the face cast, focusing on the nose area and transforming it into an Orc-inspired creature from the film Bright, refining form, proportion, and surface detail to ensure it translated effectively as a wearable prosthetic. After sculpting, cap plastic was applied in thin layers to both the positive and mould sections to seal the surfaces and prepare them for casting. The final appliance was cast in silicone, with part A and B mixed with deadener and pre-pigmented to match the model’s skin tone for a realistic finish. Once cured and demoulded, the prosthetic was applied to the model and painted using alcohol-based pigments, applied with brushes and flicking techniques to build natural skin texture, variation, and depth.