Shells for prostheses and other devices are created by a method comprising: a) providing a mandrel suitably sized and shaped for forming a desired shell； b) applying a coating silicone dispersion to the mandrel by spraying the silicone dispersion at less than 207 kPa (30 psi)； c) allowing evaporation of at least a portion of the solvent in the coating silicone dispersion； d) repeating steps b) and c) until a silicone shell having a desired thickness is formed； e) at least partially curing the silicone shell； and, f) removing the silicone shell from the mandrel.
