It is only a few more weeks before Deadpool is released on Blu-ray and DVD — though the film has already made its digital debut. Given how big of a push the movie’s marketing campaign made up to and even after its theatrical debut, some would assume that fans have seen most of what we’re going to see from the Merc With a Mouth.

As it turns out, there’s still a little more for the film to show, particularly about how Deadpool actually came together. A new video showcases the technical wizardry and craftsmanship that went into the mask that was such a big part in bringing the character to life. The video even includes details on some unexpected customizations that made working in the mask easier for Ryan Reynolds.

The video, posted to IGN‘s YouTube channel, gives fans a behind-the-scenes peek at how Deadpool’s mask was actually made. Starting with a 3D scan of Reynolds’ face, the mask was designed on a computer before being brought to life through a mix of sculpting and 3D printing. Everything had to be right, from the shape of the eyes to the thickness of the head. One of the many details mentioned in the video states that getting the mask right was so important to the design team, they started working on it before they had even been officially awarded the project.

ryan reynolds deadpool2 Deadpool Featurette Shows How the Merc With a Mouths Mask Was Made


One of the most interesting parts of the mask’s design is that the eyes of the mask were designed to be removable. A release on the back of the mask allowed the crew to swap out eyes for alternatives that were easier to see through or allowed more airflow during action sequences or other shots. Any obvious differences between the different eye panels could be corrected using CGI when animating the eyes for the final product.

Perhaps the most unexpected part of the video was seeing just how the mask (and the rest of the costume) came together, and just how much 3D printing was involved. While it’s understandable given how important having just the right shape was to the costume team, you usually think of armor and more solid materials being 3D printed in movies. It just goes to show how far 3D printing for costuming has come in a relatively short period of time.

There have been a number of behind-the-scenes tidbits released for Deadpool, which seems fitting for a movie that was made in the first place because a pitch reel got leaked online. Each one reveals a bit more of the care and attention to detail that went into making the movie what it was, and that may be what set it apart from so many other movies in its genre. Despite its eventual success, most of the people involved with Deadpool saw it as a labor of love… and that paid off big time.

Next: Deadpool Director: Studios Not Ready for Spider-Man/Deadpool Crossover

Deadpool hits Blu-ray, DVD, and 4K Ultra HD formats on May 10, 2016. X-Men: Apocalypse opens in theaters May 27th, 2016, followed by Wolverine 3 on March 3rd, 2017, and unannounced X-Men films on October 6th, 2017 (possibly Gambit), January 12th, 2018 (possibly Deadpool 2), and July 13th, 2018. The New Mutants is also in development.

Source: IGN