How Bodysuits Are Made WITHOUT VFX!

Hollywood uses a variety of different techniques to change an actor's appearance. From Make-up and wigs to fat suits and prosthetics, they've invented and perfected hundreds of different techniques. But it's when the actor needs a different body type which can't be disguised or hidden under clothing that we see the real magic of Hollywood!
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Technique
The first step in creating an ultra-realistic bodysuit is to create a "lifecast" of the actor's torso. 2 types of silicone rubbers are used, the green silicone contains an oil that prevents the actor's body hair from adhering to it, the oilless blue silicone is then applied on top and then both are wrapped in a temporary plaster jacket to cure.
Once dry the plaster cast is then carefully removed and the mould is used to create a fibreglass mould that gets covered in clay ready for the next step.

Sculpting
Here, artists work with human anatomy models and concept artwork of the director's ideas and begin sculpting the clay, forming muscles and veins, the belly button and nipples, in this stage, attention to detail is incredibly important as any slight error made now will be magnified later. The veins, for example, had to be incredibly subtle because otherwise, they would stand out too much once painted. Once they are happy with all the detail, they cover it in a thicker silicone to make a mould. This mould is then combined with the "lifecast" mould and a foam latex is injected in-between. The exterior layer of foam latex is then covered in a skin-colored layer of silicone.

Paint and hairs
The Painter begins by finding the actor's skin tone and then matching it. Although everyone has their own skin tone, this tone varies depending on the area of the body, how much sun it gets or how the light reflects off it. Everybody,s skin has red tones because of the blood, blues from the veins but also greens, browns and pinks.
If the bodysuit is for a mans-scaped bodybuilder it would be finished after paint, but if it's for a fat hairy guy there's even more detail to be added.
A belly isn't just a bulge, it has weight to it. They add bags of beads to the inside of the suit in order to mimic this weight and so the belly has some "bounce".
Hairs have to be sewn into the suit individually, respecting growth patterns and also density, knowing, understanding, and being able to apply all these subtle differences add to making the suit look ultra-realistic.

VFX
Yes, I know we said "without VFX" but sometimes it is necessary. You see, clever usage of prosthetic beards, necklaces and gloves, are great ways to hide the seams of the suit around the neckline and the hands but sometimes the suit's zipper, for example, just can't be hidden and that when the usage of VFX is needed.

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