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DIY Halloween Mask Feature Image

DIY Halloween Mask

Behind the Mask Halloween how-to project

How to make Halloween Mask

Whether visiting comic-con, a masquerade ball or even trick or treating for Halloween, with a Wagner Furno heat gun and Fosshape fabric you can create a stunning costume and disguise. Fosshape is a fiberous material that can be sculpted and shaped using a heat gun. Begin with a styrofoam bust (they come in all shapes and sizes at the craft store) to make the perfect form from sculpting a mask. This is an easy 20 minute project once you have the supplies.


Gather Your Materials

Place all your materials on a clean, dry work surface. Cut the Fosshape to fit enough fabric around the face and sides of the Styrofoam head.

Supplies for Mask

Place Fabric on Bust

Stretch the fabric over the features of the bust and place pins around the perimeter to hold the Fosshape in place.

Stretch fabric over bust

Heat Surface of Fabric

With the heat gun set to low, hold it two to three inches above the surface of the fabric and move the heat gun across the entire surface. It will take only seconds for the fabric to harden the mask.

Use the heat gun to form the mask

Heat Fabric to Hold Shape

Heat the fabric until visible shrinkage begins to take place. Do not hover in one place for too long as excess heat can discolor Fosshape.

Forming the mask

Paint and decorate the mask

Remove the pins and take the mask off the Styrofoam head. Trim and add details with mini scissors. Paint the mask with acrylic paint and team with a hooded cape or hat to finish the effect. Or you can leave the mask white to use as a shelf bust.

Mask Final
Products Used


Fosshape fabric

Sewing pins

Styrofoam head

Acrylic paint


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