How I Make a Puppet [Part I: Sculpting Kieren’s Head]


People often ask how exactly it is that I make my dolls…or as I call them, puppets, as I often use them for animation.

In this post I will go over brief steps of how I made my recent Kieren Walker puppet (a character from the BBC Three series In the Flesh). Learn more about the series here: [What is ‘In the Flesh’?]. Kieren Walker is played by actor Luke Newberry and so of course the doll is in his likeness. (fun fact! I chose to post this today on February 19th because it is in fact both of our birthday! I thought that was neat.).

These steps will be loose as they’re not really meant to follow along like a DIY but rather give some insight on how I do what I do.

We start with a sketch. This puppet was one of my easier ones because I had a subject to work from as it was a character from a pre-existing television program, rather than something entirely from scratch like I’ve done with previous puppets of mine. Luckily I had already done a few drawings of characters from the series beforehand to see what they would look like in my style.

Then I went and found a few images of the character from the series to work from like this one below.

In the Flesh ©2013-2014 BBC Three and Dominic Mitchell

Then I begin the puppet. I start with the head. The first step involves forming essentially a ball out of tin foil. I use baking clay for the head so foil is great because it can be cooked. The wad of foil also saves clay and gives you a basic structure to work around.

After I have the ball of tin foil mashed into the shape of the face and neck I begin to work on the clay. I take small pinches of the clay and begin to mold it onto the foil. I mush a good layer over the foil and then add up on top of that with more clay to form out the facial features, nose, brows, lips, eyelids. I was very drawn to sculpting this character because of how prominent the actors facial features are, high cheek bones, sharp nose, noticeable ears and furrowed brow. I sculpt the face back to the ears and then stop.

sculpey clay over foil (for the face)


Once that is created it is time to bake. For this amount of clay I gave it ten minutes in the oven at 275°F. After that is done I give it just a little bit to cool enough so that I wouldn’t burn my hands but not enough to get rock hard.

I then work from the back and sculpt in the hair, where I move to the front and sides to add in the front swoop and sideburns. I wanted the face to be hard enough that I wouldn’t mess it up while working on the hair, but soft enough that the clay would merge on the second bake. I then have what you see below.

Next step is the paint! …for those of you who don’t know, Kieren Walker is a zombie. Or as they call them in the series “Partially Deceased Syndrome Sufferers.” This means I didn’t have to add too much color as he’s very pale and washed out to begin with. I did however need to add eyes, brows, hair color, and shading.

It started with some light washes a cream tone on the face. Then I painted in the hair, brows and crevices with a nice light coffee brown.

After the paint of the face and hair had dried I worked in some white for the eyes. Kieren has two different colors shown on screen at times, one with his brown contact and one with his exposed zombie eye. The pupils and brown I drew in with pen after the white paint dried.

The end result of the head is below as well as the final head attached to his body and comparison.

I hope you enjoyed this little journey, and I’ll be sure to go over how I create the body and clothes eventually! Until next time check out a few clips from In the Flesh, which is one of my favorite television programs.

The series is centered on a zombie apocalypse, but is approached differently than most other zombie rising stories. It follows a recently risen zombie, Kieren Walker (a gay, 18-year-old who committed suicide) as he is rehabilitated into regular society where he experiences bigotry and isolation due to his zombie status. As more and more zombies begin to be rehabilitate we meet an interesting array of characters, both living and dead. The series involves many social issues, from mass panic, to suicide, depression, PTSD, gay relationships and family issues. It is definitely worth checking out.

I’ll leave you with two of my favorite scenes:

You can purchase the first and second seasons on

Tell me what you think of my puppet and In the Flesh below!

Until next time!

damian alexander