Research; How Mannequins Are Made

It takes about a month to make one mannequin, and this is the process in which they are made:

  • A model is used to pose in the correct position
  • The armature (structure to support clay) is constructed out of aluminium wire
  • Wood and clay are added for structural support
  • The build up of the clay structure starts
  • Clay head is then attached
  • The hands and feet (if required) get life cast (using dental alginate) then attached to the figure
  • After the final clay has been smoothed, a plaster waste mould is then required to each limb (clay etc cut off)
  • Layer of plaster then goes on
  • Mould is then soaked to aid the separation of the two halves of the limb
  • Clay is then removed from the inside
  • Head and torso are casted with plaster
  • Put the figure back together with some final refinement. Figure is then finalised (spray grey)
  • Then gets sent to the mould department. A fibreglass resin production mould is then made by laminating layers of resin and glass-fibre.
  • The master figure is made so when the original wears down, another can be made (identically)
  • Master figure then gets sanded down
  • Production figures then get made and are laminated in the same way as the master figure
  • Spray painted to the desired colour
  • Optional additional make-up can be applied by specialists
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