Construction Details:

The head was the most intensive part of this costume. I started with heavy gauge wire that I made the base shape of the mask with, after which I covered the entire thing in a metal mesh. I used plaster bandages to sculpt the head from there. There are three layers of bandages and another layer of plaster over those to help smooth out the bandage-like texture they had created. I carved the eyes out at the first layer so I knew where they would be, and re-molded the mouth a couple times to find the expression that worked best for the character. It was finished with gesso and some light grey paint to bring dimension to the features. The inside of the eyes are a mesh fabric, and inside the head there is a simple lighting rig with one LED through the left eye to give the "glowing eye point" effect that Sans has in the original game. I'm wearing a black mask underneath to hide my neck and hair.
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nThe gloves are hand stitched and then painted with the skeleton pattern, the legs are tights done in the same way. Aside from that the shoes, hoodie and pants are all purchased, and there is alteration on the hoodie to make it fit well.

Personal Thoughts:

This costume was made to go along with my cosplay partner's Underswap Sans! It was surprisingly satisfying, ive never made a full head mask before and the experience was incredibly relaxing for me as a crafts person at heart.

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