Ministry of Masks produce collector quality latex masks for an array of purposes. First established in a shed in the garden of founder Tom’s South East London home, the company has expanded its range since 2012. Until now, creating each mask type has required the sculpting of a clay model to produce a plaster mould from which latex casts can be taken. The client approached ITERATE to assist with the use of new manufacturing technologies to streamline their creation process.

A review of existing data on human head dimensions was conducted which led to the conclusion that the in-house SLA printer (stereolithography apparatus) couldn’t achieve the scale required, whilst outsourcing fusion jet technology was an expensive route. Therefore, in-house Fuse Deposition Modelling (FDM) proved the best technological compromise. A test print was produced to ensure there were no failed areas given the mask’s sophisticated geometry and to ensure a successful delivery of the desired fit and function. To fit the bed size, the design was strategically dissected into four individual sections which were printed and precisely bonded together to achieve minimal visibility of the split lines.