Mold taken from an actor's body or body part using alginate or silicone – used to create custom-fitted prosthetics, creature suits, and stunt doubles.
What is a Body Cast?
A Body Cast (Körperabguss, Life Cast) is a cast of a body or body part, used as a basis for creating prosthetics, creature suits, and special effects parts. The process captures the exact shape and texture of the skin surface.
Casting Materials
| Material | Use |
|---|---|
| Alginate | Classic, skin-friendly, fast |
| Silicone | Highly detailed, reusable molds |
| Plaster Bandages | Support shell (Mother Mold) |
| Acrylic Alginate | Longer working time |
| Body Double Silicone | Professional standard |
Types of Body Casts
| Type | Application |
|---|---|
| Face Cast | Facial prosthetics |
| Head Cast | Full head including ears |
| Hand/Arm Cast | Limbs |
| Torso Cast | Chest, back |
| Full Body Cast | Creature suits, stunt doubles |
Process (Face Cast)
| Step | Description |
|---|---|
| Preparation | Protect hair, apply Vaseline to eyebrows |
| Straws | In nostrils for breathing |
| Alginate Application | Layer by layer, from the center outwards |
| Curing | Wait 3–5 minutes |
| Mother Mold | Plaster bandages for stabilization |
| Removal | Gently release |
| Pouring Positive | Create positive from negative mold |
Safety and Comfort
| Aspect | Measure |
|---|---|
| Breathing | Keep nostrils clear |
| Eyes | Closed, remove contact lenses if necessary |
| Communication | Agree on hand signals |
| Claustrophobia | Discuss beforehand |
| Allergies | Material test beforehand |
Time and Effort
| Cast Type | Duration |
|---|---|
| Face Cast | 30–60 Min |
| Head Cast | 1–2 Hours |
| Hand/Arm | 20–40 Min |
| Torso | 1–2 Hours |
| Full Body | 3–5 Hours |
From Negative to Positive
| Step | Material |
|---|---|
| Negative Mold | Alginate/Silicone |
| Mother Mold | Plaster, fiberglass |
| Pouring Positive | Ultracal 30, Hydrocal |
| Curing | Overnight |
| Demolding | Negative destroyed or reusable |
Using the Positive
| Application | Description |
|---|---|
| Sculpting | Prosthetic design on cast |
| Mold Making | Create production molds |
| Fitting | Test fit |
| Reference | For digital models |
Challenges
| Problem | Solution |
|---|---|
| Air Bubbles | Careful application |
| Cures too quickly | Cooler water |
| Hair sticks | Thorough preparation |
| Distortion | Mother mold stabilizes |
| Discomfort | Breaks, communication |
Costs (approx.)
| Item | Price |
|---|---|
| Face Cast | 150–400 € |
| Full Body Cast | 1,000–3,000 € |
| Material (Alginate, 2kg) | 40–80 € |
| Ultracal 30 (25kg) | 30–50 € |
Digital Alternatives
| Method | Situation |
|---|---|
| 3D Body Scan | For VFX, not for prosthetics |
| Photogrammetry | Reference, not for fit |
| Combination | Scan + physical cast |
Today
Body casts remain indispensable for high-quality prosthetic work. Despite digital technologies, a physical cast is the only method to create perfectly fitting appliances – the foundation for any convincing character transformation.
More in the lexikon