Search using the terms "latex" "life casting" "mold making" or
"casting materials. " Available from large art supply houses. The
latex I used many years ago came in a bag that contained crumbed
hydrated latex. You melt them in a double boiler, and then you can
pour this over your face. The melting point is fairly low, around 110
degrees F. Make sure you put straws in your nose so you can breath
while the latex is cooling and setting. Tape a cardboard retaining
barrier around your head. Make sure your hair does not get in the
stuff!

Then from the mold, you can pour plaster of Paris into it and make a
positive of your face. This is also called a "death mask." I made
several masks of my face to preserve what i look like when I was
young, including a dummy head.

Looking at the supply catalog again, I notice that you can just brush
the stuff on, and then peel it off, to make a mask of your face.

A friend who was helping me could not stop laughing after she poured
the latex on my face because it was as if my face disappeared! For
her, the experience was weird!

I'm sorry that I did not save the cast latex mold however. It started
to shrink, and so I ground up thinking I could reuse the material
again. However, it was difficult to reuse. If you let the mold
dehydrate, you will get a replica mold of your face, except it will be
in miniature! So, the next time I do this, I will make sure to save
the mold and let it dry out.

Also, make sure you are not allergic to latex!
Source(s):
http://www.artmolds.com/category28.cfm

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To make a latex mask molded specifically an individual's face, one must follow a two part process. First a plaster face cast must be made of your subject. Second, the plaster face cast is then used to sculpt the mold for the final latex mask.

The plaster face cast process:

The subject reclines in a chair, has his or her hair protected by a skull cap, and has plaster of Paris placed over the head (breathing facilitated, typically, through straws placed in the nostrils). This is usually done in two parts--front and back. The division may be established through the use of a template of the top-to-bottom outline of the head and neck of the person being 'cast,' with a parting compound such as a lubricant being placed on the template to enable the easy separation and removal of the two parts of plaster. After the two parts have been removed and have been allowed to dry, they are re-united to form a 'female' mold into which plaster may be poured to re-create the image of the original cast head and features, in 'male' or 'positive' form.

The molding of the character mask:

Once the male or positive mold has been made the split external halves of the female mold is split off. The new 'positive' is carefully removed and cleaned. It is altered and sculpted through the superimposition of modeling clay that builds upon the original 'male' mold to establish different features for a final, external character mold that itself will be re-cast.

The mold is re-cast to form a hollow negative of the design and latex rubber is poured in and allowed to sit for a short time before the excess is poured out.

After the latex rubber has dried inside the mold, it can be peeled out and painted as desired. What comes out of the mold is now the 'positive' version of the latex mask, formed fit to the face of the person originally cast.
Source(s):
http://www.ehow.com/how_4583273_plaster-face-cast.html
http://www.instructables.com/id/How_To_Cast_a_Face_in_Plaster/
http://www.costumes.org/advice/costcraftsmanual/tmpjk4.htm

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