Thane Krios Cosplay Part 1 – Materials & Getting Started


With the release of Mass Effect Andromeda nostalgia struck me. The original Mass Effect series shaped the gamer I am today and has influenced my artistic styling for years now. As a cosplayer, the only way I know how to show homage to this series is by recreating my FAVORITE character from the original ME games: Thane Krios.

Now Thane is not a very easy character to tackle. For starters, he’s an alien. Yeah, yeah, people dress like Asari all the time and I’ve even seen my fair share of Turian’s but I challenge you to find ONE decent Thane Krios mask or SFX appliance online. Go ahead…I’ll wait.

Didn’t find one, did you? You may have found THIS incredible artist’s work but she only made two masks and both sold long ago. Even if I DID find a face for Thane there is the tiny problem of me gender swapping him. I’m not interested in attempting to bind my breast OR try to reduce to curvature of my hips for this cosplay. It will already be uncomfortable with all the pleather, spandex and makeup required so gender swap him I shall!


For this build I have to break it into two parts: Facial Appliance and Costume.

Facial Appliance Materials

  • Head Cast of yourself OR a sturdy mannequin head that matches your measurements.
  • Monster Sculpting Clay in Medium Hardness.
  • Sculpting Tools
  • Reference Images of Thane (you can find these by searching for “Thane Krios Turn Around”).
  • Bowl (to heat up the clay and capture shavings).
  • Heat Gun (to heat up clay in controlled areas).
  • Platinum Cure Silicone (there are different cures, check out Reynold’s Materials).
  • Smooth On 305 Resin (for your mother mold).
  • Mold Release
  • Filler (this helps the resin/silicone go farther)
  • Silc Pig (to pigment your silicone).
  • Mixing Bowls and sticks
  • Gloves
  • Eye protection
  • Respirator or mask
  • Sculpey or water based clay (for building your mold wall).
  • Playing cards or Card Stock (for building your mold wall dividing line).
  • Alcohol based airbrush paints (I use ProAiir, Body Ink and/or Endura).
  • Airbrush (I prefer a gravity fed one as it uses less paint).
  • Time

Costume Materials

  • 4 Way Stretch Pleather ( I prefer Spandex World)
  • 4 Way Stretch Pinstripe Spandex
  • 4 Way Stretch Hexagonal Spandex (Yaya Han’s line has some of this).
  • 4 Way Stretch Brown Spandex OR Lycra
  • White Piping
  • Foam (to make the collar rigid and create his metal neck accent).
  • 4 Way Stretch Black Spandex
  • Snaps OR Velcro
  • Elastic
  • Green Nylon (for the back cut out) OR Green spandex
  • Sewing Machine
  • Sharp sewing needles
  • Black and White Threads
  • Sewing Pins OR Clips
  • Patterns OR Muslin to create patterns
  • Fabric Scissors
  • Fabric Markers OR Tailor’s Chalk
  • Patience


Now that you have your materials you can start sculpting! Since this is the most difficult part of the costume I started with it but you don’t have to. To give you an idea of how messy/ugly sculpting looks before it’s cleaned up here are some before and after photos…

Don’t be afraid to make adjustments and take your time with this. Speaking of…I best get back to sculpting mine! Be on the look out for Part 2 next week!


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