To make the foam latex mask, you need to have a positive in Ultracal that you will sculpt on. If it's a puppet's face I guess a positive to sculpt on--But it's got to be in Ultracal 30, because you will need to bake it for 3-4 hours. And your positive needs to have proper keys and a lip so you can clamp your molds together during baking. I don't though...but you still need to have that lip...
Once you have the positive to sculpt on, you will sculpt your puppet's face in a clay--I have used KleanKlay and Monster Clay with success. Perfect that sculpt. Create an Ultracal mold of this. When you pry apart your mold, you will essentially destroy your sculpt, so your mold has to be perfect the first time. You need to make sure there are no air bubbles in that first layer...You can find YouTube instructions on mold making. Until you make it first hand, a lot of the jargon may go whoosh over your head...but don't let that get to you. Keep at it.
Purchase your foam latex kit, which has everything you will need. In addition, you will need a dedicated convection oven, and 10-speed mixer to whip up your foam latex. You should not use this for food ever...and you need to cook this outdoors because the fumes are dangerous/cancerous. Foam latex has ammonia in it. You will need a hygrometer to verify that the humidity levels aren't going to affect your batch. You need an oven thermometer to make sure that your temps are within the range...a stopwatch to time your latex mixing...lots of prayer cause everything's expensive....
You need to prep your molds before mixing the foam latex by cooking them about four hours each...to get rid of any humidity within your Ultracal 30. Any humidity will give off pockets of steam that will destroy your baked foam latex. You need to spoon your foamed up latex into your molds...trying to avoid air bubbles...and doing this within a 3 or 5 minute window, depending on humidity levels and also your chemistry of the foam latex...
Once you get your materials purchased, you will have dropped about $330 minimum. Kits cost around $75. Ultracal costs around $45 but shipping is frickin' expensive so if you can find something local it's better for you.
If you want a list...I can dig it out for you and send it via PM. It's a barebones list. You have to make sure your convection oven is large enough...or that your two-part mold will fit in there.
1:1 clothing is tricky because it needs to be fitted properly. You can have a pattern and sew it exact, but final tailoring needs to be fitted to the person.
