Greetings, fellow animation enthusiasts! I've been crafting puppets as a hobby for about 8 years now, and I'd like to share my latest creation. He's a heavily stylized Orc-type character. I used the traditional buildup method, beginning with an aluminum wire armature with epoxy putty "bones" and a lip mechanism for expressive motion. Each muscle was painstakingly hand-carved from medium density foam and applied accordingly. Latex skin patches were applied throughout, and several coats of tinted latex of varying shades were dabbed on for a nice skin texture. The teeth and tusks were sculpted from epoxy putty and coated with clear epoxy after painting. Eyeballs were made from plastic beads, which I painted and coated in epoxy. The face itself was initially sculpted in plasticine and then cast in latex for extra detail. This was a tremendously fun project (~40 hours of work) and I'm pretty happy with the results.
I decided to sell him in order to fund my future projects and puppet fabrication. He's currently up for auction, so if anybody here is interested or knows somebody who might be, feel free to take a look. I'm currently working on transitioning to steel ball-socket armatures and silicone casting.
As a side note, I'm becoming very interested in doing commission work and building custom puppets for those who just want to jump straight into animation (I've found that I actually enjoy making puppets more than animating them, hehe).