Writer/puppeteer Mary Robinette Kowal has an excellent piece on papier-mache.
Papier-mache is one of the oldest forms for creating puppets and so a lot of people think that there must be something better out there. Actually, there are very few contenders. Done well, papier-mache is light, strong, fast, and non-toxic. I know, we’ve all had the experience of the lumpy paste, and corners that stick up and a thing that requires years of sanding to even resemble smooth. It doesn’t have to be that way. I’ll show you a technique that will only need three layers and can be danced on.