Sculpting: The first step is to create a clay or digital sculpt of the desired facial features. This sculpt serves as the basis for the final silicone mask. The sculptor carefully crafts the shape, texture, and details of the mask to achieve a realistic appearance.

Mold Making: Once the sculpt is complete, a mold is created to capture the sculpted details. The mold is usually made using a two-part mold-making material, such as silicone or polyurethane. The sculpt is coated with a release agent before applying the mold material to ensure it can be easily removed once cured.

Casting: Once the mold is complete, it is prepared for casting. A special effects artist or mask maker pours a liquid silicone material into the mold, ensuring that it fills all the details and contours. The mold is then left to cure, allowing the silicone to solidify and take on the shape of the sculpt.

Demolding: After the silicone has cured, the mold is carefully removed, revealing the cast silicone mask. Any excess material or imperfections are trimmed or sanded away, and the edges of the mask are refined for a smooth finish.

Painting and Detailing: The silicone mask is then painted and detailed to enhance its realism. This involves airbrushing layers of high-quality silicone paints to create natural skin tones and texture. Additional details such as veins, wrinkles, or scars may be added to further enhance the mask's realism.

Hair and Accessories: Depending on the design, the mask may require the addition of hair or other accessories. Synthetic hair or individually punched hair may be applied to create eyebrows, facial hair, or even a full head of hair. Any other desired accessories, such as glasses or prosthetic pieces, can also be attached.