Prosthetic Nose / Makeup appliance

myminifactory

At NIDA's prop and object production department, we're always pushing the boundaries of theatre and TV, often venturing into prosthetic makeup appliances. I recently attempted creating a prosthetic using digital techniques alone, intrigued by the rapidly evolving world of manufacturing where jobs are being automated or done digitally. This piece was started with a skannect scan (photogrammetry), refined in Zbrush, and finished in Rhino and netfabb before being cast in silicone and quickly painted. While this specific design is a witch's nose, due to my limited experience with Zbrush, the same process could be applied to create realistic limbs and skin for individuals with injuries or missing limbs instead of traditional makeup effects. The design can easily be split in netfabb to accommodate any print bed size. To produce the prosthetic, first print both parts of the mold and remove any stray plastic. Next, mix 60 grams of silicone or another soft rubber and pour it into the mold's portion. While the silicone is still liquid, press the nose scan (or buck) into the cavity and circular key. Apply pressure using a mold strap or light clamping until the silicone cures. Once cured, open the mold to find the nose fits perfectly on the scanned individual, demonstrating the potential of this digital manufacturing process in creating life-like prosthetics.