How does one make realistic silicone mask eyelids for attachment to animatronic mechanism?

Looking for some direction - videos, tutorials, etc.  I have created a mold and my first mask from this original form:

However, the eyelids were - of course - too thick, and I discovered the hard way that Exacto knives work but are somewhat inelegant (note roughness, jagged lines, huge gaps between mask and eyeball):

Since I have the mold, I can make new masks easily enough.  I am planning to make an internal impression in the mask to set thicknesses properly so that things should fit, but I need to be able to create eyelids that are soft & stretchy enough for the small servos I have in my occular assembly to be able to blink them realistically:

I saw your video of using Slacker encased between the two mask components layered with something like DragonSkin, but I could really use some much more detailed help with the eyelid making process, especially since the original lifecast is - of course - closed-eye.

Thanks very much for what help you can offer.  This certainly looks like the best place to find answers to this issue.  I'm really wanting to make this look amazingly life-like and realistic.  I've learned a lot in the past year or two, can't stop now! 



  • I would try casting the eyelids on their own, then blend them into the face. This way you can cast up different thickness and test various eyelid designs to find out what works best for you.

  • This sounds viable - can you offer me some pointers (remember - complete beginner here) on where I can get "eyelids" to cast?  Or would this be something I'd need to sculpt from some other material then cast...?  I assume I'd adhere the eyelids to the mask with a good silicone adhesive like SilPoxy?  And then blend by painting some mixed silicone over the seams to blend?  Any videos here (or other sites) you can recommend that would show this process in detail?


  • edited March 2020
    I would sculpt the eyelids and make a 2 part mold of them.  You could also open up that 2 part mold (or just make a single open mold) and layer in silicone to make eyelids of different thicknesses for testing.

    And you are correct, a silicone adhesive is what you need, and blending with some silicone paint to hide the seams.

  • Thanks.  Any videos that would depict this process...?  Seems straightforward enough, but I've learned that straightforward sounding things in this field are usually anything but to a noob :)

  • We don't have any courses that focus on casting eyelids, but our silicone transfer appliances lesson focuses on casting thin silicone pieces, which might be of help:

    You would not need to make the molds out of a clear material, since you are not casting them as transfers, so you could use any kind of mold material you are comfortable, like a urethane resin or stone.

  • Thanks very much.  I'll probably sign up and watch several of the applicable videos - they will all be useful I expect.


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