Building Process Page 1 - Page 2

Before I begin, I would like to thank my begining and advanced puppetry and my costume design class teacher, Mimi Mace, of Humboldt State University. Most of the puppetry making techniques I know today I can attribute to what I learned from Mimi. She was an excellent teacher and a fantastic advisor. Thanks, Mimi.

The first step of building the puppets was collecting enough foam for the heads. Foam can be expensive, costing around $25 a yard. I got lucky and found two old single foam mattresses. I glued them together and then cut out the blocks of foam needed for the project.

The next step involved using my drawings as a guide and sculpting each piece of foam. For sculpting tools I started with an electric carving knife (the type you use for carving turkey), and for the detailed work, I used a pair of scissors. Pinching the foam and ripping it off is a good technique as well. Needless to say I made a huge mess of foam pieces.


Some of the heads, carved and ready for the next step.

After carving each head, I would also cut out the mouth and chin. This would have them ready for the next step: "Skinning the Head." Or at least that's what I came to call it.

To skin the head I would wrap the sculpted foam with a large, loosely fit piece of muslin. Then with patience and time you fiddle with the fabric enough to get it to fit the shape--creating a pattern. Actually I started to get pretty good at it by the 11th head.

The next step is taking the muslin pattern and transfering it to the fleece. I didn't have the highest quality fleece as I was asked to keep the puppets under a certain price. Given a higher budget and knowing what I know now I would look for fleece that was more stretchy.


Building Process Page 1 - Page 2