We begin construction by taking your approved costume design and create detailed pattern pieces. These pattern pieces are carefully logged and stored. If you would order another costume after delivery of the first, we can exactly duplicate your custom character costume. This allows us to produce a single mascot costume or hundreds of the same mascot.
The pattern pieces are used to cut the various materials needed to produce the custom costume.
Our custom character heads are created by taking lightweight, industrial foam and sculpting them into the required shape. By utilizing this type of construction, we are able to produce extremely large heads, while minimizing the overall weight. Our heads come with a fully adjustable head harness that maximizes stability and control, while maximizing comfort.
After the foam head is created, it is covered with a variety of high quality fabrics and imitation furs. The facial features are added, according to the artwork provided. Ventilation and visibility is usually provided through screened areas of the eyes and/or mouth, although the specific design may require a screen panel to be added.
This type head construction provides an extremely strong head that will spring back if accidentally crushed. It will maintain its shape for years to come.
The body may or may not have additional shaping. The body shaping is provided by sculpted foam, either whole body shaping or body portions, such as belly padding or shoulder and chest padding
In some cases, there is no separate head in the design. The design incorporates the head and body in one piece. This design would be created utilizing sculpted foam as the entire custom mascot shape, with the outer shell of the mascot constructed of various types of fabrics, often utilizing the sublimation process to replicate a specific logo or design.
In this type of construction, shoulder supports are usually added to maximize control and stability of the mascot.
Arms and legs are often constructed of heavy-duty spandex type fabric, unless the mascot costume is an animal, then the arms and legs, of course, are made of the same imitation fur as the rest of the body.
The custom costume hands are usually oversized and padded to accentuate the shape.
The feet are constructed of sculpted foam, covered with various fabrics and imitation fur. They all have internal elastic straps to maximize control and long wearing crepe rubber soles.
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