Why not make a fabric tree? Here's what I'm thinking...you want a big tree, so the child can fit inside. So you paint tree bark on 8' x9' muslin. Cut and finish a window opening and then sew two fabric sleeves into the top and the bottom--insert hula hoops in the top and the bottom. Now you have a cylinder painted like tree bark. You will hang the top hula-hoop after you paint an upward looking view of a tree on the ceiling (so you paint a forest floor view of the tree canopy). You can even hang a few non-painted leaves to hang down from the ceiling (cut them from green felt).
Fabric can be kept safe (no sharp chickenwire, no toxic substances) and is washable. I suggest latex/acryllic fabric paint or wall paint (non-toxic) on unsized fabric.
Your son can either lift the hoop up to get inside, or you can leave an opening in the back as an entrance. If you want to get fancy, you can even cut exposed 'roots' from felt, bend them in a 'v' shape so they stick out and let them drape on the floor.
If the hole in the tree were positioned right, you might even have a creative puppet theater. In a pinch it could also be a storage area for stuffed animals.
Or you can velcro woodland creatures to the tree (woodpeckers, worms, caterpillars, squirrels, wasp nest) so that the whole surface is a creative experience.
If you want to be even fancier, you can make the upward painting in the tree to include the inside of the tree (a squirrel's eye view) inside the diameter of the tree fabric cyclinder--so maybe tree rings, or the insects that live in a tree.
Oh and you could also do it with corregated cardboard--George Pettit does some fantastic stuff with cardboard. If you doubt it, check out http://www.cortecscenery.com/ - http://www.cortecscenery.com and look at his directions. Cardboard is much safer for a child than heavier materials, and as George does this, its a wonderful construction material with high quality results.
If you prefer to look up casting methods, I think you are referring to a technique called 'vacuum forming' (also called 'plastic forming'. Vacuum form pieces are commonly used to stage armour, or for bricks to attach to walls, etc.. You might not need to cast it yourself, there may be tree casts. Some of the places that have the armor: http://www.merchantadventurers.com/ - http://www.merchantadventurers.com/ . http://www.costumearmour.com/ - http://www.costumearmour.com/ . http://www.tobinslake.com/ - http://www.tobinslake.com/ . I'd think tobin lakes is the most likely to have a tree cast.
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