Creating a custom Halloween mask with vacuum forming

Nick Douillard is an American artist known for his whimsical “blobs”: playful, abstract figures that sit somewhere between sculpture and character design. His work spans a wide range of materials and techniques, blending creativity with humor to produce pieces that are instantly recognizable and full of personality.

Nick has been experimenting with MY YARD vacuum formers for quite some time, using them in past projects such as his ghost blob sculpture and blob nightlight. His latest creation takes a seasonal twist: a spooky, hand-crafted Halloween mask made using his MY YARD FORMART 2 vacuum former and a HIPS plastic sheet.

Every great mask begins with a great mold. Nick starts by sculpting the mask shape from clay, carefully planning the placement of the eye holes to ensure clear visibility when worn. Once the clay mold has dried, it’s ready for vacuum forming.

The beauty of this approach is that the artist can give each mask its own personality, from eerie smiles to expressive contours, all shaped by hand before forming begins.

Using his FORMART 2, Nick heats a HIPS sheet (High Impact Polystyrene) until it reaches forming temperature. The sheet is then vacuum formed over the clay mold, capturing every detail of the sculpted surface.

After the forming process, the mask is carefully removed from the mold, and any excess plastic is trimmed away. HIPS is an ideal material for this kind of project: it’s durable, lightweight, and can be easily painted or decorated, making it perfect for custom masks, cosplay pieces, and decorations.

Once the mask is shaped and cleaned up, Nick adds his creative finishing touches: paint, textures, and, of course, his signature playful flair. The end result is a one-of-a-kind Halloween mask that combines fine art with hands-on making.

This project showcases how vacuum forming can be used beyond traditional manufacturing. For artists, makers, and hobbyists, a vacuum former opens up exciting possibilities for creating custom props, decorations, and wearable art.

If you’re interested in art, sculpture, or experimental design, Nick Douillard’s work is a constant source of inspiration. From his quirky blobs to imaginative light fixtures and masks, his creations demonstrate how technology and creativity can work hand in hand. Follow Nick Douillard on YouTube and Instagram for more of his inventive projects, behind-the-scenes videos, and playful artistic experiments.

Machines

• MY YARD FORMART 2 vacuum former

Materials

• Clay
• HIPS sheet