1) You need to be able to see out of your costume.
No matter how excellent your costume looks, it'll be less impressive if you're stumbling around blindly. Picture a Hollywood monster tripping on things and feeling its way around. This is even more important than being able to hear or be heard while in the mask. You need to be able to navigate your surroundings. Consider whether you can always get a clear view through the mask or if the headpiece keeps falling over your eyes. Failing that, have your buddy guide you around.
2) Your costume needs to have mobility.
Despite shoes or skirt, you need to be able to walk normally... if not run or climb stairs. Or dance, if you can do that regardless of costume! If you're wearing something with high heels or stilts, practice in a safe place before appearing anywhere in public. You need to be able to use your hands well enough to pick up something to drink or turn doorknobs, even if you're wearing gloves or trailing sleeves.
3) Your costume needs to have ventilation.
In large, elaborate costumes such as mascot suits, overheating is a serious risk, so these will often need a cooling-fan system. Suffocating in one's mask is far less common, but should still be taken into consideration. Don't forget those air holes.
4) Your costume needs to be modular.
That is, large portions of it can be removed. Usually this is divided up by upper body, lower body, mask, and prosthetic limbs such as wings or tail. This is important for if you're in an emergency, or if you'd just like to regain some mobility and fresh air for a rest.
5) You need to be able to drink while in your costume.
If you've got an elaborate mask or facial prosthetic, you'll want to be able to drink some water while still wearing it. That might mean using a straw. As mentioned before, overheating is a risk, so stay hydrated. In a large costume, you can even conceal a water pack (1-3 liters) inside it, with a straw hidden inside the mask, so you can always have water when you need it without spoiling your visual effect.
6) You need to be able to use the lavatory.
Well, you do. If you're in a hurry, having to disassemble most of the costume first is a real nuisance... and if you designed your costume in such a way that you'd need help to get into or out of it, you'll regret that. Remember: always plan ahead for this kind of thing when you're designing the costume.
7) Your costume needs to be able to fit through normal doorways.
Otherwise your grand entrance... isn't. Turning sideways or ducking is acceptable, if possible. Having to remove modules for temporary mobility is last resort, and often considered bad form, since this can spoil the [stage] magic of a well-constructed costume. You might send your buddy ahead as a scout to find a larger door. You might find a concealed back door, disassemble, enter, and reassemble before anyone sees you. The flashiest solution is a large costume with collapsible parts, such as pneumatic wings that can open and close.
8) You need to be able to sit down while wearing your costume.
That might mean removing some modules of it- the sweeping tail, the bussel, the wings. Sitting down could either be just for a rest (which you'll want in one of the heavier costumes) or to take a ride in a car. (Remove that towering headpiece.)
9) You need a buddy to accompany you while costuming.
Your buddy may be without costume, or just wearing a far simpler one than yours. They'll be familiar with how your costume works, so they can give you a hand with it if needed. If you're in an emergency they'll help get it off you. They'll act as a sort of bodyguard. In exchange, let them know of your undying gratitude for being the most important safety feature on the list.
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This page written by Orion Sandstorrm. All original content. Feel free to contact me if you've got any questions about this material or want to use it. Please do not copy or distribute any portion of this material without my permission.