Mask Sizing

Head Measurements for Proper Mask Sizing

Using a set of calipers, follow these illustrations as a guide to taking proper head measurements. After each point is taken from the head, place the calipers on a ruler and record the measurement in inches. You can check your nearest pottery supplier or art store for a set of cheap calipers.

Click Here to download our caliper template

Measuring with Calipers

It is imperative that all four measurements are taken to fit a mask properly. If you correctly take the measurements as shown below, you will have the necessary information to purchase a properly-fitted mask. Although taking a tape measure and wrapping it around your head is not as accurate as the caliper method, we have included a sizing guide for a general fit.


Mask Sizing Reference Guide

We match your head size to one of our 5 existing shell sizes.

This guide will help you determine your approximate size
in our masks.
Caliper Method
Mask Size Cheek Jaw Head Side Head Depth
Junior 4 -4.25 3 - 3.5 5 - 5.5 6.5 - 7
Small 4.25 - 4.75 4 - 4.5 4.75 - 5 7.75
Medium 5 - 5.5 4.5 - 5 5.25 - 6 7.75
Large 5.5 - 5.875 5 - 5.75 5.875 - 6.5 8
X Large 6 - 6.5 5 - 5.75 5.875 - 6.5 8

Tape Measure Method
Mask Size
Junior 52cm to 54cm
Small 53cm to 56cm
Medium 57cm to 58cm
Large 59cm to 60.5cm
X Large 61cm to 62cm

Correct area to measure cheek

This is the most important measurement. Measure the highest point of the cheek bone just in front of the ears.

Correct area to measure cheek

This photo highlights the area where the shell contacts the face, which is where you want to take your measurement.

Incorrect area to measure cheek

As illustrated in the photo above, measuring at this cheek point results in a measurement that has no contact with the mask shell.

Correct area to measure jaw

Clench your teeth and feel for the muscle at the point of your jaw. Don't be afraid to apply pressure to the calipers. You want to measure the width of the jaw bone, not including skin and fat.

Correct area to measure head side

As illustrated in this photo, measure 1.5 inches above and center to the ear.

Correct area to measure head depth

Plaster Head Mould

To begin preparing for the plaster cast you must have the following apparatus: Plaster bandages, Vaseline (petroleum jelly), Nylon stocking, Hair conditioner and Plastic food wrap (Saran wrap).

Start with applying a generous amount of hair conditioner to your hair. This will eliminate any bonding of plaster to the hair through the stocking.


Stretch the stocking over your head so it's just above the eye brows and covering the ears as shown in figure 1. Apply vaseline to entire face area, paying attention to eyebrows and facial hair. It's a good idea to place small pieces of Saran wrap over the eyes to cover the lashes and any other area containing hair.


Cut all plaster strips to approx. 7 inches in length. Start with 2 strips placed diagonally across the face from cheek across nose to forehead as shown in figure 2.


Cover mouth area and up along the sides of your head as shown in figure 3.


Make sure to leave nostril area open for breathing as shown in figure 4.

stick straws up your nose or in your mouth!!! This is extremely dangerous, and there is no need for this method. Simply leave an opening to breathe from your nose and or mouth depending on if you're a mouth or nose breather. You will be in a stagnant position for over 30 minutes so it is important to determine this before hand.


The entire head cast only needs to go as far back on the head as the end of the ear shown in figure 5, and down the chin to the Adams apple shown in both figure 4 and figure 5.