Making a Cable Controlled Animatronic Mask (Mountain Gorilla)

Creating a sculpture of a gorilla’s head in WED clay. This sculpture is modelled on top of a head cast and designed to have a performer’s own eyes incorporated into the mask design.

Preparing a WED clay sculpture for moulding in fibreglass. Sealing the sculpture and dividing it up into mould sections using metal shim. Incorporating keys into the shim.

Fibreglass mould making: applying polyester resin gel coat and laminating with fibreglass matting to produce a lightweight but durable mould.

Making the mould is only half the job. Once the fibreglass is cured, we tackle the messy process of trimming, opening and cleaning up the mould.

Creating a skin for animatronics requires a core to be fashioned inside the mould. This lesson covers the steps of modelling an appropriate skin thickness inside the mould and casting the core in fibreglass.