As well as solid resin pieces, I have a history of making large, characterful sculpted full heads.
Each mask was originally sculpted from scratch in either WED clay of Monster Clay for their client, or for myself. Then with their moulds created, they are cast with an latex skin and expanding foam inside for support and comfort.
These are an more involved process than a lot of mask creation, however, the benefits of longevity, reuse and detail all happily make up for the extra effort.