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Home / Blog / What Mascot Head Is Right For You?

What Mascot Head Material Is Right For You

Many details can affect how a mascot costume works and how easy it is for a mascot performer to wear. One of the biggest decisions to make in the mascot design process is the material for your custom mascot head. There are two different options you can choose from: traditional sculpted foam and vacuum formed plastic. Both mascot head materials have advantages and disadvantages, and in this article, we will compare each one based on the following criteria:

  • Appearance
  • Sanitation
  • Longevity
  • Weight
  • Ease of Replication
Traditional Sculpted Foam Vacuum-Formed Plastic
Appearance
X
Sanitation
X
Longevity
X
Weight
X
Ease Of Replication
X

Vacuum Formed Plastic Mascot Head: 

The vacuum formed plastic head is the most common head option used. The plastic mascot heads are created by vacuum forming over a permanent foam mold. For a visual representation on how we create vacuum formed heads, watch here! Though a little heavier than sculpted foam, the vacuum formed plastic head offers the most accurate replications, ease of cleaning, longevity, and they are adjustable to different performers.

  • Appearance: The vacuum formed plastic head allows for the greatest amount of detail and contour in a head design. Expressions and facial features are much more defined with a molded plastic mascot head.
  • Sanitation: Plastic mascot heads can be easily cleaned and sanitized by wiping them down with a disinfectant wipe or a solution of water and a mild detergent. Since the helmet with chinstrap is installed on adjustable brackets, the helmet can be removed to be cleaned or replaced.
  • Longevity: Due to the durability of the material, a molded plastic mascot head will typically have a longer lifespan than mascot heads made out of foam materials. In addition, because it is easy to clean, it reduces build-up of sweat and odors that occur over time.
  • Weight: The plastic mascot heads can be up to two to three pounds heavier than other types of mascot heads. A helmet with chinstrap is installed on brackets, so it can be moved up and down or on an angle for optimal vision. If the head is very large, it can be installed on a padded shoulder harness for support.
  • Ease Of Replication: Because the plastic mascot head uses a permanent mold, replication is easy and cost-efficient for the customer. Duplicates of a plastic head are less expensive than a foam option. Learn more about our replication process here!
Progression how a vacuum formed plastic mascot head is created using a Money Joe mascot head mold.

foam, the vacuum formed plastic head offers the most accurate replications, ease of cleaning, longevity, and they are adjustable to different performers.

  • Appearance: The vacuum formed plastic head allows for the greatest amount of detail and contour in a head design. Expressions and facial features are much more defined with a molded plastic mascot head.
  • Sanitation: Plastic mascot heads can be easily cleaned and sanitized by wiping them down with a disinfectant wipe or a solution of water and a mild detergent. Since the helmet with chinstrap is installed on adjustable brackets, the helmet can be removed to be cleaned or replaced.
  • Longevity: Due to the durability of the material, a molded plastic mascot head will typically have a longer lifespan than mascot heads made out of foam materials. In addition, because it is easy to clean, it reduces build-up of sweat and odors that occur over time.
  • Weight: The plastic mascot heads can be up to two to three pounds heavier than other types of mascot heads. A helmet with chinstrap is installed on brackets, so it can be moved up and down or on an angle for optimal vision. If the head is very large, it can be installed on a padded shoulder harness for support.
  • Ease Of Replication: Because the plastic mascot head uses a permanent mold, replication is easy and cost-efficient for the customer. Duplicates of a plastic head are less expensive than a foam option. Learn more about our replication process here!
Traditional Sculpted Foam Mascot head of a bear.
Mascot designer gluing on custom mascot fur onto a foam mascot head.

Traditional Sculpted Foam Mascot heads

Traditional foam mascot heads aren’t as common, but their biggest advantage is that they are relatively lightweight. Foam options including stiff foam, open-celled foam, or a combination of both can be used for traditional foam mascot heads. Pieces are cut from the foam and then cemented together to form the head.

  • Appearance: With traditional foam, our mascot team designs these mascots 100% by hand. This handmade process gives foam mascots a bold, animated look with larger features that really stand out in a crowd. Note that our standard mascots are still hand crafted, we just utilize some tools to give us a jump start. While very fine details can be more challenging to achieve in foam, the result is a fun, expressive character that captures attention.
  • Sanitation: Regardless of the type of material you choose, you should always be cleaning and sanitizing your mascot head to ensure longevity. For foam materials you will have to give a little bit more love and care. Due to its porous nature, foam hold odors and sweat easier. With the right care, though, your mascot will stay clean, comfortable, and ready to perform. To know how to properly clean your mascot head, check out this blog here!
  • Longevity: Like formed plastic mascot heads, sculpted foam will last you years. Unlike plastic though, foam will naturally soften and gradually break down due to its material. This process is very slow and usually isn’t noticeable early on in your mascot use. After years of use though, you will start to notice a slight change in shape. Luckily though, here at Olympus, we are prepared for this and offer refurb services to restore your mascot head so it looks good as new.
  • Weight: The biggest advantage of a foam custom mascot head is that it is lightweight, weighing 2 to 6 pounds on average.
  • Ease of Replication: Since our foam mascots are handcrafted, creating a duplicate also requires the same skilled, hands-on process. Our mascot team is excellent at their job and has mastered the art of replication but there is of course some room for human error when duplicating foam mascots. Additionally, it’s necessary for you to send in your current mascot head so we can capture every detail in the replication process. While replication can present unique challenges, it’s nothing our team hasn’t seen before.

In summary

Both mascot head materials are great options for your custom mascot. Depending on what you and your performer are looking for, one option will suit you better than the other. Either way, with over 50 years of experience, we will ensure that you get the perfect mascot head for your custom mascot costume. To learn more about mascot heads check out these two blogs: Mascot Head Cleaning Guide and Mascot Vision: Inside a Mascot Head!

Get in Touch

Looking for a custom mascot head? Olympus Mascots has been crafting custom mascots for over 40 years and has created 17,000+ mascots during that time. Whether you need a plastic or foam mascot head, our experienced mascot team is ready to get your mascot head project started. Contact us to get a mascot head quote today!

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