Steampunk Carnival Battle Mask
Artist: Danny Ashby
He explains how he made this mask in his artist’s description:
I sculpted onto a plaster cast of my face in Roma Plastilina, molded it in rubber, cast it in wax, and then dipped the wax in a silica slurry shell mold. I then cut open the bottom of the shell mold and fired it in a furnace, to first melt out the wax, and then to fire it into a ceramic like density which is very resistant to extremely high temperatures. My foundry class then filled the mold with molten bronze (a task which takes a team of many people). Then once it cooled down, I set to work smashing off the shell with a hammer and chisel and sawing off the gates which allow the bronze to flow into the mold. Then I sand blasted it and cleaned it up further using a bench grinder and a dremel tool. After that, I polished the surface with a variety of sand papers and steel wool to achieve a smooth surface. Next I drilled and tapped the holes for the bolts to secure the straps and hinges. Then I applied the patina, which involved heating the mask with a propane torch, then spraying on the liver of sulfur in layers, applying the torch until it was a solid black. I then buffed the highlights back out with a scotch rite pad and steel wool.
Read the rest at the source.