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The mask was built by the costume effects department, using a digitally mapped model of Tom Hardy’s face and skull. Costume effects supervisor Graham Churchyard explains, “To us, the Bane mask had to fit like a prosthetic; however, unlike a prosthetic, it had to look like it was engineered out of metal. We were able to take Tom’s computer cast and 3D model each rigid piece to the contours of his head so it was tight to his face, with no gaps.”

As it turned out, “tight” was an understatement. Hemming attests, “It was gripping Tom’s head like a vice. With his assistance and patience, we made it as tight as it could ever have been. There was a magnetic removal panel on the front, so everything you see has a series of magnets underneath it, and everything beneath that has a rubber seal that pressed into Tom’s skin and was held on by tension. The fact that he tolerated it, let alone acted with it, was astounding.”

Hardy says, “I didn’t feel limited by the mask. What’s cool about it is, as soon as you put it on you become the character.” 

from the 50 pages TDKR production notes

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