I needed a quantity of small skull faces for another project build, and came up with this solution
Air drying Clay (DAS for instance)
Skull to cast from
Rolling pin or similar (I used a small length of PVC pipe)
Clay modeling tools
The skull I am casting from is a styrofoam skull, 4 inches high.
Cover the skull with the aluminum foil
take a block of clay from the pack and roll out to a thickness of between 1/8 and 1/4 inch
Cover the front of the skull with the clay.
Shape the clay to the skull, removing any excess clay as you work the clay
Add details (teeth etc) using modeling tools
I only needed the skull fronts so trimmed excess from the skull
Because the drying time is around 24 hours and wanting to continue casting, I carefully removed the foil from the skull, removing the cast as well. You may need to slightly reshape your cast after removing.
Once the clay is almost dry, you can remove the foil from the cast
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