Quote Originally Posted by curious aardvark View Post
I use openscad - and it's really easy in that :-) I've made a lot of moulds using this technique. The hard part is always going to be getting the model of the head in the first place. Layer lines will be an issue. most 3d plastics sand fairly easily. Just remember to sand by hand. dremel type sanding drums spin too quickly and the friction melts plastic. I have yet to sand fast enough by hand to melt pla :-) As fred says - an hour or 2 sanding a mould is well worth it, as you can get lots of head moulded from one printed mould. The other way would be to make a head and create a mould with plaster of paris - or whatever the modern stuff is. One head will let you make a lot of moulds. So 6 of one and half a dozen of the other really :-)But it is viable and the kit isn't that expensive. Relatively speaking :-)
Thanks to you and the others, I feel much better about this project now, much more informed.