I mproved stone, epoxy resin, polyurethane, silicones, and linotype metal molds have advantages and disadvantages in the fabrication of facial prostheses.’ Improved stone molds may chip, break, or crack; lose their high surface reproducibility; have poor compressive strength; and are less ductile than metal molds. Silicone and polyurethane molds have low yield strength and easily tear.’ Epoxy molds do not readily adapt to other systems and require overnight cure.3,4 Linotype metal molds seem to be the most popular, but they are the most difficult and time consuming to make, require numerous materials in their manufacture, and are heavy.5 Choy et al.” have detailed the advantages and disadvantages of different metal mold preparation techniques. This article describes a technique for production of highly accurate metal molds in a relatively short time. The technique uses hot air to spray molten metal onto a prosthesis pattern, thus creating an excellent metal reproduction of its surface. The sprayed metal layer is then reinforced with an autopolymerizing casting resin. The metal spray process was developed over 50 years ago. The process used two electrically insulated wires with an arc completed across their ends. As the arc melted the wire, the molten alloy was blown away from the arc with a large volume of compressed air. The process is still used for manufacturing large molds and for spraying high melting-point metals. The metal chamber spray gun, developed about 20 years ago, has been refined continually. It has a gas or electrically heated chamber in which alloys are melted and atomized with a small volume of compressed air in the same manner as paint is sprayed. Another spray process includes a high temperature plasma flame into which metals are introduced as wire or’ powder. This process is not customarily used for making molds, because the temperature of the target material is raised excessively. It is mainly used for metallizing or repairing worn machinery. The M-80 metal spray gun (Arconium Corp. of America, Providence, RI.) used in the present technique contains an alloy melting chamber heated by a propane