At NIDA (National Institute of Dramatic Art) where we do prop and object production for theatre and TV we also get into some prosthetic makeup appliances. This here is my first attempt at putting together a prosthetic using only digital techniques. I felt this was an interesting study into the quickly changing world of manufacturing where many jobs are being automated or done digitally.
The piece here was started using a skannect scan (photogrammetry), cleaned up and sculpted in Zbrush, then finally finished in Rhino and netfabb. I've cast the final piece out of silicone and given it a quick paint.
While this is a witches nose, due to my lack of Zbrush expereince, the same process could be used to produce realistic limbs and skins for persons with injuries or missing limbs instead of makeup effects.
The design can be easily split in netfabb to accomodate any print bed.
To use the mold print both parts and clean up any stray plastic.
Mix 60grams of silicone or another soft rubber, and pour into the mold portion.
While the silicone is sill liquid, squash the nose scan (or the buck) into the cavity and the circular key.
Apply pressure with a mold strap or light clamping until the silicone is cured.
Once cured: Open to mold to find the nose fits the scanned person