Cosplay: How to Make a Superhero Mask!

Make a super hero mask


It can be really pricey to purchase a custom made super hero mask online. It’s nearly impossible to find a suitable mask at the costume store. The only possible solution is to learn how to make a super hero mask.
Or super villain. Your choice.

Skill Level Required


  • One sheet of foam
  • One Styrofoam wig head ($5 @Sally Beauty Supply, no need to get fancy here)
  • Mod Podge (glossy)
  • Masking tape
  • Blow dryer


Now, when one looks at this list, it may seem like a lot just to make one mask. But I currently use the wig head to keep my wigs, and the Mod Podge for many other projects. Also, a sheet of foam will usually yield two masks. In the long run, it’s not as pricey as it can seem.

1. Cut the mask shape.

CAM00947I started out with cutting the mask. You’ll need lots of patience for this part.

You will also need to look at sample pictures for this. The internet is a wonderful resource for pictures of masks (but I’m sure you knew that). For this mask, I was looking at pictures of the Black Canary mask from Arrow.

Use a pen on the wronCAM00946g side of the foam to draw out the shape you need.

After cutting the shape, you’ll need to cut the eye holes. This is the hardest part. Start by cutting a small hole in the middle and then cutting towards the edges. It doesn’t have to be perfect, you can always even it out after cutting out the triangular chunks.



3. Get gluey!

Use double-sided tape to stick the mask to the wig-form. Use a brush or sponge to apply mod-podge all over the front of the mask. Try to get it as even as possible. But even if you aren’t able to get it completely smooth, no worries – it’s typically clear when it dries.


3. Get Fired Up!

Heat up your blow dryer and/or heat gun. Heat the mask with the blow dryer.


4. Shape the mask!

Apply a thick layer of Mod Podge to the center of mask (bridge of nose, between the eyes). Heat this section till dry and repeat in this area multiple times. You may need to pinch and mold the different areas where you want detailing. The bridge definitely needs the most work though.

Continue over the rest of the mask


By the end of the day, you’ll have a flexible but solid and form-fitting mask!

One Comment on ““Cosplay: How to Make a Superhero Mask!”

  1. Ben

    Can I just say! You are awesome! And I find it awesome that you list The Doctor on your list of interests! YAY for Timelords!

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