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Several months ago, I approached the rapid prototyping department at my company and asked if they would be able to help me produce a replica Ironman helmet. I had tried building the helmet with pepakura files produced by a member of the thereplicapropforum.com, but I found I did not have the time/patience/skill to sit and trim out hundreds of pieces of paper and reassemble them. This is my first instructable, but I wanted to share my process for anyone who has been interested in going this route. I took photos and screen caps along the way, but I may have missed a few steps that I'll just have to explain.
UPDATE:
I received word from user mangomango that there were problems with the original file. I've broken the original file into its constituent pieces and labeled them as such. The Ear piece is the same on each side of the head, so just make two of those!
I've added a zip file with an STL of the ironman helmet pieces for others to use. Please credit the Replica Prop Forum and I, if you use!
Several months ago, I approached the rapid prototyping department at my company and asked if they would be able to help me produce a replica Ironman helmet. I had tried building the helmet with pepakura files produced by a member of the thereplicapropforum.com, but I found I did not have the time/patience/skill to sit and trim out hundreds of pieces of paper and reassemble them. This is my first instructable, but I wanted to share my process for anyone who has been interested in going this route. I took photos and screen caps along the way, but I may have missed a few steps that I'll just have to explain.
UPDATE:
I received word from user mangomango that there were problems with the original file. I've broken the original file into its constituent pieces and labeled them as such. The Ear piece is the same on each side of the head, so just make two of those!
I've added a zip file with an STL of the ironman helmet pieces for others to use. Please credit the Replica Prop Forum and I, if you use!
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Signing UpStep 1: Modeling
As I mentioned, I had gotten the pepakura helmet file from the RPF forum. I had also purchased a copy of the Pepakura software. With a full version that allows you to create files rather than just view, I exported the pepakura file as an OBJ which I could would with in Maya. The conversion process was easy, but because the pep file is meant for paper usage, it was relatively low resolution and had no thickness.
The first step, while the poly count was low, was to extrude the model inward to give the helmet thickness. Thickness is important, it provides stability to the final product which can be brittle when it is printed too thin. Because I planned on wearing this, (and probably walking into walls/doors/people) I wanted it to be thick enough the handle a bit of abuse. The final helmet varies in thickness because while the outside has grooves and ridges, I wanted the inside to be smooth. That way, the sides and bottoms of the grooves would have extra material around then to prevent fractures. The overall helmet averages between .125" and .25" thick.
When I was done adjusting the silhouette of the low poly helmet, I subdivided the model to provide a smoother finished surface. As you'll see later, I could have gone even further with this step.
The first step, while the poly count was low, was to extrude the model inward to give the helmet thickness. Thickness is important, it provides stability to the final product which can be brittle when it is printed too thin. Because I planned on wearing this, (and probably walking into walls/doors/people) I wanted it to be thick enough the handle a bit of abuse. The final helmet varies in thickness because while the outside has grooves and ridges, I wanted the inside to be smooth. That way, the sides and bottoms of the grooves would have extra material around then to prevent fractures. The overall helmet averages between .125" and .25" thick.
When I was done adjusting the silhouette of the low poly helmet, I subdivided the model to provide a smoother finished surface. As you'll see later, I could have gone even further with this step.
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I am loving the design for this, but I was wondering how much the printing cost you?
i got the complete armor make in foam ,but your helmet finish is really awesome tacte
i search for 3d printing in my town now ,heheheheh
when you need the armor suit template desingn ,you can say me ,ok?
bye and regards from spain and from rpf forum
i am getting a printer soon and the build area is only 6"x6"x6" and i was wondering if it would fit.
I've broken the entire model down into piles the size of the printer bed like I've shown for the helmet. All together including the helmet, there are 16 piles, each one taking 8-10 hours to print, then a varied amount of time to depowder. That process is basically vacuum loose powder out of machine, then airbrush each piece to remove powder from crevices. Usually then the pieces are hardened with epoxy, but because I'm doing so much other sanding and painting, I'm told them that part isn't necessary.
Winning the Object printer and supplies would reduce my reliance on their services and would really help me along the way with the business plan I've been working on to provide low cost custom 3D prints to architects/designers/model builders/makers/sculptors/etc. Without the cost of repaying a $50,000 loan driving my price, I can keep prices lower! I've made this terrifying graphic to show what I have left at this point.
If you do end up releasing them, could you tell me what scale the files are (with respect to the original files)? I'm 5 feet 8 inches (normal build), and I just want to make sure there's some loose compatibility there.
Thanks again man, you're really helping the prop community here with a creative alternative!
http://store.solidoodle.com/index.php?route=product/product&path=59&product_id=56
http://store.solidoodle.com/index.php?route=product/product&path=59&product_id=56