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In the course of making a hat, helmet, glove, boot, breastplate, what-have-you, the making of a mockup is an essential step in the process. A mockup allows you to see a three-dimensional shape of the piece and fit it to an actor; it gives you a "canvas" onto which the designer can manipulate scale of aesthetic elements. I try to make mockups from something as close in nature to the final material--vinyl or heavy felt mockups for leather items, poly jersey for knit caps, thin craft foam for Fosshape thermoformable felt pieces.
If a piece is likely to be needed in rehearsal, it's helpful to make the mockup in such a fashion that it can be finished off and used as such.
Here are some images of mockups: armor, hats, boots, and more...

Armor mocked up in heavy cardstock. The final thing will be stiffened leather.

Boots mocked up in heavy felt. The final pair will be leather.

Vacuform helmet base with cardstock design elements.

Hat mockups in muslin, flannel, thin buckram.

More hat mockups, "finished" for rehearsal usage.
If a piece is likely to be needed in rehearsal, it's helpful to make the mockup in such a fashion that it can be finished off and used as such.
Here are some images of mockups: armor, hats, boots, and more...

Armor mocked up in heavy cardstock. The final thing will be stiffened leather.

Boots mocked up in heavy felt. The final pair will be leather.

Vacuform helmet base with cardstock design elements.

Hat mockups in muslin, flannel, thin buckram.

More hat mockups, "finished" for rehearsal usage.