In each episode of DiResta (every other Wednesday), artist and master builder Jimmy DiResta (Dirty Money, Hammered, Against the Grain, Trash for Cash) lets us into his workshop, to look over his shoulder while he builds whatever strikes his fancy.
Vacuum forming is the perfect technique to make repetitive objects—like a Halloween mask!
In this video you see a technique I use with my students. I give the assignment to create a mask form for the Vac Former. To make it durable and strong I use plaster and to keep the sculpt fluid and natural I use a soft clay.  When using a negative mold as you see here in this video, you will always get a perfect  form each time. You can see that I use a thin styrene  to show the fine details in the plaster that originated in the soft clay.
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