Using Rubbing Alcohol
Open the compact and place it in a plastic, resealable bag. This will help keep your work area clean. It will also catch any loose bits of powder. If you don't have any plastic, resealable bags, cover the broken powder with a sheet of plastic wrap. Make sure that it is wrapped firmly over the edges, or the powder will escape. This method will use rubbing alcohol. The rubbing alcohol will evaporate, and leave behind the hardened powder. It is considered safe, but if you have very sensitive skin, you might want to consider the method.
Break the compact up into a fine powder, including the not broken parts. Use a spoon, mini spatula, or the base of a makeup brush to do this. Keep smashing the powder until you end up with a fine dust. Make sure that there are no clumps or chunks left, or your compact will be very grainy. This may seem like you are only making things worse, but it will help give you a smoother finish in the end.
Take the broken compact out of the bag, or pull the plastic wrap off. If any powder got out, try to carefully tip it back into the compact. Break it up into a fine dust, if necessary.
Add some rubbing alcohol to the powder. Depending on how big the compact is, this could be as little as a few drops, to as much as a capful. Use enough rubbing alcohol so that the powder is damp, but not so much that it starts to float. Try to use at least 70% rubbing alcohol. The higher the percentage, the faster it will evaporate/dry. If you added too much rubbing alcohol, dip the corner of a tissue into it. The tissue will soak up the excess rubbing alcohol.
Let the rubbing alcohol soak in for a few seconds, then smoosh it around. You can use the end of a makeup brush or a mini spatula to do this. Keep smooshing the powder around until you get an even, creamy consistency. There should be no clumps or chunks.
Place a piece of plastic wrap over the wet powder, then smooth it down with your finger to shape it. The plastic wrap will help keep your finger clean while you work. You can also smooth the powder down with a spoon, the base of a makeup brush, or any other smooth object.
Remove the plastic wrap, and press down on the powder with a tissue. Make sure you use a tissue that will not easily break when wet, otherwise you risk getting tissue particles in your compact. Avoid pressing too hard, or the powder may crack. This will help remove any excess rubbing alcohol. To get that brand-new, pressed look, use a scrap of cotton fabric instead. It will leave behind that fabric-like texture many brand-new makeup powders have.
Remove the tissue, and clean up the edges with a thin brush, if desired. If you'd like your work to be neater, take an eyeliner brush, and run the point around the edges of your powder. This will help give you those nice, crisp edges. Don't worry about cleaning up the compact case itself just yet.
Leave the compact open, and let the powder dry overnight. During this time rubbing alcohol will evaporate, leaving behind the caked powder.
Clean up the compact using a q-tip dipped in rubbing alcohol, if desired. While you were restoring your broken powder, you may have gotten some makeup powder "mud" on your compact case. If this bothers you, dip a q-tip in some rubbing alcohol, and wipe the dried "mud" off.
Using Pressure and Steam
Turn your iron on and set it to the highest temperature. It is possible to set broken powder using just pressure, but it will be very fragile. The heat from the iron will help set the powder further and make it more durable. Because this method contains no rubbing alcohol, it is safe for sensitive skin. Most compact powders will come in a metal pan set into a plastic tray. Make sure that your compact powder has this metal pan.
Break up the compact powder so that you can dump it out. You can use anything hard, such as a toothpick or fork. This may seem like you are only making things worse, but it will help give you a smoother finish.
Transfer the broken powder into a plastic, resealable bag, and zip the bag shut. Make sure that you get all of the powder out. If you need to, use a toothpick or the end of a fork to get the powder out of the corners. You will be breaking the powder up further inside this bag.
Break the powder up further into a fine dust. The easiest way to do this is to simply press down on it with the flat side of a fork. You can use anything you'd like however, even a spoon. Make sure that there are no clumps or crumbs however; the powder must be very fine. If you leave any clumps or crumbs, your finished powder will be very grainy.
Pull the metal pan out of the compact case. Most powdered makeup will come in a metal pan that is glued into a plastic case. You will need to pull this metal pan out before you move on to the next step. The easiest way to do this is to hook a butter knife under the lip of the pan, and then pry/pop it out. If you don't pull the pan out, you will risk melting the plastic tray.
Pour the powder back into the metal pan. Open up your resealable bag, and tip the powder into the pan. Don't worry if you lose some powder.
Press the powder into the pan with a spoon. Place the bowl of the spoon onto the powder, and press down on it until it becomes firm. Start around the edges of the powder, and work your way towards the center. Try not to push any of the powder out of the pan. When you are done, the powder should be packed firmly into the pan. At this point, the powder may look as good as new, but it is very fragile and may shatter again with the smallest bump. You will need to set it further using heat.
Turn the iron off. By now, your iron should be nice and hot. Turn it off and unplug it. This is very important. It will ensure that no water gets into your powdered makeup, which can ruin it. Make sure that the steam option on your iron is turned off. You want to use dry heat.
Press the iron into the powder for 15 seconds. Make sure that you are pressing down as hard as your can. Do not move the iron up-and-down or side-to-side like you would when ironing clothes. The heat of the iron will help "set" the powder.
Lift the iron, wait a few seconds, then press it down onto the powder for another 15 seconds. When you lift the iron, you may notice that your powder is looking a lot smoother already. You will need to do the pressing process one more time, however. Again, make sure that you are pressing down hard, and that you are not moving the iron around.
Let the powder cool, then glue the metal pan back into the plastic case. While the pan cools, swirl some glue inside the cavity in the plastic case. Then, carefully lift the metal pan up, and press it back into the plastic case. Wait for the glue to dry before closing the case.
Finished.
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