Hornet, from the game 'Hollow Knight: Silksong':


v1.0 (molded MDF mask): PDF assets.

v2.0 (carved foam mask + MDF sword): OnShape assets.


v1.0 (molded MDF mask, shown): use PDF assets to cut 3mm MDF to shape (do not cut gap between horns, nor eye-holes, as this impedes next step); soak MDF in hot water for 15-minutes, then strap around 160mm pipe 'former' until dry; cut gap between horns, and eye-holes; cover eye-hole area with heavy-denier stocking fabric + glue; use PDF assets to cut 1mm cardboard skin; VHB skin to MDF chassis. Mask is secured to head with 3-point webbing harness.

v2.0 (carved foam mask + MDF sword): use OnShape assets (a pair of each 'Guide' part) to guide foam cutter + smooth by hand; use OnShape assets to cut 12mm MDF sword (Needle) + chamfer + paint.


All Hornet assets by Chris Molloy are licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.