Standard Mask Sizing Reference Guide

For standard “off the shelf” orders, we match your head size to one of our 5 existing shell sizes.

This guide will help you determine your approximate size for our masks.

Tape Measure Method

Measure the circumference around your head just above your eyebrows. If you do not have a soft tape measure, wrap a piece of string or lace around your head, then lay the string flat and measure the distance with a metal tape measure or ruler.

Mask Size Measurement   Measurement
Extra Small 49cm to 52cm
Small 53cm to 56cm
Medium 57cm to 58cm
Large 59cm to 60.5cm
Extra Large 61cm to 63cm

Supply Your Own Mould

It is possible to make your own mould and having a mask custom fitted by using the instructions further down this page but we advise that you contact us first.

Custom Fittings

Custom fittings are done using a mould of the front half of the head.  We offer custom fittings by appointment only. Please contact us for details and/or to book an appointment.

The Mask Building Process

goalie mask moulds
Head Moulds
goalie mask moulds
Goalie Mask Moulds
fibreglass kevlar raw mask
Raw Fiberglass/Kevlar Mask
goalie mask shells
Finished Shells
goalie mask painting
Prep and Paint
goalie mask antibacterial foam padding
Antibacterial Foam Padding


Make Your Own Goalie Mask Mould

To begin preparing for the plaster cast you must have the following items:

• Plaster bandages cut into 7 inch strips
• Vaseline (petroleum jelly)
• Nylon stocking
• Hair conditioner
• Plastic food wrap (Saran wrap)

Start by applying a generous amount of hair conditioner to your hair. This will eliminate any bonding of plaster to the hair through the stocking.

goalie mask mould sportmask
Figure 1

Stretch the stocking over your head so it is just above the eye brows and covers the ears as shown in Figure 1. Apply Vaseline to entire face area, paying special attention to eyebrows and facial hair. It’s a good idea to place small pieces of Saran wrap over the eyes to cover the lashes and any other areas containing hair.

custom goalie mask
Figure 2

Start with two plaster bandage strips placed diagonally across the face from cheek across nose to forehead as shown in Figure 2.

sportmask goalie mask
Figure 3

Cover mouth area and then cover vertically along the sides of your head as shown in Figure 3.

nhl goalie masks
Figure 4

Make sure to leave nostril area open for breathing as shown in Figure 4.
WARNING! DO NOT stick straws up your nose or in your mouth!!! This is extremely dangerous. Leave an opening to breathe from your nose and/or mouth, depending on what is most comfortable for you. The cast takes over 30 minutes to set so it is important to determine the best location of the breathing vents before hand.

goalie mask mould
Figure 5

The entire head cast only needs to go as far back on the head as the end of the ear, as shown in Figure 5, and down the chin to the Adams apple as shown in both Figure 4 and Figure 5.