Silicone Face Casting

The first version of the face cast was both a success and a failure. The face actually does fit onto the skull and the magnets hold it in place, but the casting method and the mould are very crude and the edges are dirty. Thin silicone walls caused air bubbles to get trapped in unfortunate places and when the mouth opens the skin is pulled away from the eyes so there will need to be more magnets under the eyes to prevent this from happening... there is a lot to be learned from this. The skin needs to have a certain thickness to look and feel right and not stretch too thin and let the skull shine through (even if it's not realistic). The next iteration will reduce a few parts on the skull and make the wire attachment mechanism for the jaw simpler as well. The best part is no part.

Overall I can see though that with a little better execution this might actually work.