How about something truly original for your Halloween costume this year.  A mask that's hand-made by you, for example. As an added bonus, some of the pieces shown below can be used for wall art.
Instructables has a collection of "40 DIY Halloween Masks." Here's a "Scary Mask" by scoochmaroo.
Keep in mind that, if you and your friend try a face casting but it doesn't go well, you can always laugh about it in the years to come.
-- Marge
Instructables has a collection of "40 DIY Halloween Masks." Here's a "Scary Mask" by scoochmaroo.
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| scoochmaroo, "Scary Mask," Instructables | 
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For something more modern how about Low Poly Mask at MakerBot's Thingiverse by kongorilla.
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| kongorilla, "Low Poly Mask," Thingiverse | 
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More in the girly realm is this Fabulous DIY – Make Your Own Masquerade Mask from Scratch, at DIY & Crafts.
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| DIY & Crafts | 
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This minimal mask, called an "Ice Queen mask," is demonstrated by Klaire de Lys:
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Klaire and a number of other mask makers suggest using a face casting for the basis of a mask.  This video shows you how to make one.
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If you have questions about materials, try the Smooth-On site. There are other companies online that offer these materials, but the Smooth-on site is well-organized and has good information.  There's a page on Life-casting materials and much more.  Take a look at the materials for Special Effects and Propmaking page.Keep in mind that, if you and your friend try a face casting but it doesn't go well, you can always laugh about it in the years to come.
-- Marge
 
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