Here’s a breakdown of how a typical Ultraman “kaiju” suit is built for suit-mation filming:

 Here’s a breakdown of how a typical Ultraman “kaiju” suit is built for suit-mation filming:

  1. Sculpting & Molding

    • Clay sculpture of the monster’s form on an armature

    • Plaster or silicone molds taken from the sculpture

  2. Foam Body Casting

    • Urethane or foam-latex rubber is poured or injected into the molds

    • Yields a lightweight, flexible “skin” with creature contours

  3. Surface Coating & Seams

    • Thin layers of latex or urethane brushed on for smoothness and durability

    • Seams glued or hand-stitched; excess trimmed for a continuous surface

  4. Detailing & Painting

    • Urethane or acrylic paints add color, shading, and weathering

    • Faux fur, scales, armor plates (often made of molded vinyl) glued on

  5. Head & Facial Mechanisms

    • Fiberglass or resin shells for the head, with removable front “mask”

    • Radio-controlled or manually operated eye/ mouth mechanisms

  6. Interior Harness & Comfort

    • Mesh or nylon harness sewn inside to support actor’s weight

    • Foam padding at pressure points; small battery-powered fans for cooling

  7. Hands, Feet & Accessories

    • Thicker foam or rubber for claws, talons, boots

    • Attachable props (spikes, fins) fasten via Velcro or snaps

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