Chhau masks are crafted from paper pulp, cloth, and clay through a meticulous, multi-step process. It begins with shaping a clay model of the mask, which is sun-dried to harden. A layer of powdered ash is then applied, followed by several layers of paper moistened with natural gum. Once dried, the mask is coated again with clay, and finally covered with cloth for added strength and smoothness.

After the initial layers dry completely, the outer clay mold is removed, revealing the basic mask form. It is then polished and coated with a base layer of white paint before being hand-painted with vibrant colors. Each mask is adorned with decorations that reflect the character it represents — using wool, jute, foil, bamboo sticks, plastic flowers, and beads for embellishment.

Mask making is a family tradition in Purulia, where men, women, and even young children participate together, preserving this rich cultural heritage across generations.