Building Your Custom Mascot

Producing a custom mascot costume presents many challenges to its creators. Each character mascots  brings about something new and always deserves personal attention to details. We understand the importance in approaching a mascot design with a completely fresh outlook. At Sugar's Mascot Costumes we always consider durability, longevity, safety, comfort, and manageability!

While the majority of custom mascot costumes are constructed with their basic components such as a head, body, feet and hands, many are not…Mascots can also be large objects, such as recycling containers, bricks, eggs, bubble gum or a huge droplet of water. Regardless of the design, each mascot costume is treated uniquely.

Getting Started on the Design Concept

At Sugar's Mascots we understand that characters shine through their gestures and attention to detail.  Sugar’s Mascot costume’s has played a major role in inspiring design standards for our industry. To assist our clients in the development of a character, our art department is vital to the process. Whether your concept is clear or not we are trained to help you with its creation. We listen to the needs and wishes of the client and work through our experience we work to give you what you want! 

We are often asked to develop a character, which began in some form or another, such as a stuffed toy, logo, or advertising campaign... our function is to create a custom mascot that works well in the environment for which it is intended.  

We offer a linear sketch as complimentary artwork.  Once the job is confirmed we provide a technical sketch indicating the actual measurements.  We also provide colour renderings in some circumstances where the character or project becomes more complex.  

Moving Into Production

Once the technical drawing is approved we begin the process of building. Before we carve a stroke we’ve had a number of meetings about your character’s needs.  The sculpting department drafts their pattern in order to carve or form the different parts; head, feet or skeletal structure.  Once the head or frame is carved or assembled, digital photos are sent to the client for approval.  Once approved, we hollow the head or prepare the frame for covering. 

At the same time, fabrics have been purchased so that the wardrobe department can get busy.  They draft, cut & stitch, and design the clothing specifically for your mascot.  Throughout the process all three departments coordinate with one another to ensure that all components work together to make you the best possible mascot... 

Anatomy of Your Custom Mascot Costume

You'll appreciate the world-class quality we provide.

Head: Heads are generally carved from lightweight durable foam. An adjustable helmet is installed for balance and stability. For many sports mascots, we install our custom halos with removable sweat bands for easy washing. To answer the need for air circulation for the performer, we introduced our first fan cooled system 25 years ago.  Over the years we have refined the system.  The unit is comprised of a compact battery operated fan system that, according to our electrical engineer, this unit circulates 35 cubic feet of air per minute. Further to this we offer internal cooling and hydration vests & collars that can be worn under the costume.  The same product is used in industry and the military.

Depending on the design, the eyes and mouth of the mascot are made of porous foam reinforced with metal screening for strength. This method allows vision, airflow and conceals the face of the performer from the public. These methods have been widely adopted by the industry.   When the eyes are not required for vision, they are shaped with plastic, then painted and coated for durability.  Often we will add vision in other areas as well.  At one time we produced some cows for Sony.  Since the cows were doing a short term promotion in rush hour using public transit without a chaperone we screened the entire muzzle to keep them safe by giving them maximum vision.  


Body: Inner and outer bodies are built separately to aid in the cleaning and maintenance of the character. The inner body is constructed of soft, porous foam sandwiched between a cotton sports mesh. The structure is maintained by a series of light weight hoops.  In most cases, this allows the inner body to be washed in a standard-size washing machine. 

Sometimes we’re working with a frame rather than a body with a head. In this case we construct the inner framework from durable lightweight foam; reinforce it, then cover it with the appropriate fabric or printed material. In many cases, we’ve replicated the design of a brand, such as a beer glass or a bag of chips.  The ideas and concepts in this area are endless.

Hands: The mascot hands are lightly padded to conceal the hands of the wearer. Dexterity can be increased depending on the needs of the client.  Over the years we have lead the way with innovative design ideas.

Feet: Our feet begin with a thick rubber sole for durability.  We have made many different kinds of feet for mascot costume depending on the character’s design. Paws, cowboy boots, hooves, running shoes, skates, bird feet or fins…just to name a few!

Your Mascot is Almost Ready!

Once every step is complete, we pull it together for a full fitting & photo shoot. Here is where the department heads can make final adjustments to your costume. We send you a copy of the digital pictures and a short video of the mascot in action (again, great fodder for the scrap book or blog). Upon your approval, we carefully pack up the costume for shipping.

Mascot Costume Duplication and Multiples

Many of our clients have acknowledged the value of having multiple mascot costumes. Duplicates ensure that your mascot can attend more than one event at any given time or location to represent your organization.  Many franchises, large sporting events, theme parks, or corporations require multiple costumes to cover a wide number of geographical locations.  Sugar's Mascots keeps excellent records so that we can always ensure a consistent look in duplicated costumes.