Brother Thomas Film
Because Br. Thomas is rather portly there was a concern that his girth would interfere with the puppets ability to pose and bend. Especially if he were cast as a solid block of silicone rubber.
The solution was to give Thomas a rigid set of “storm trooper underwear” that could suspend a piece of lightweight upholstery foam between his chest and hips to fill out his middle without inhibiting movement.
The first step in building the Br.Thomas puppet was to create patterns for each of the body parts that would later be cast in flexible silicone rubber.
The images immediately below are a detail of a rough armature used to sculpt a hand and a detail of the finished hand pattern. The beautiful thing about silicone rubber is that every wrinkle, bump and fingernail you see in the finished pattern will show up with amazing accuracy in the final puppet!