I posted this on the SHH boards, but you guys here may be more interested in it:
I was curious if anyone has attempted to make the TDK mask/helmet. I was thinking of ways to accomplish this from the vantage point of one who doesn't know about casting, and I found this site:
Basically it is a site that does 3D printing (which I have done before). So I got to thinking about modeling the mask in 3D and uploading it for anyone to use. First I have to clarify and check out some things:
The best material to use out of their selection seems to be the Cream Robust, as it is the sturdiest. The maximum size of the model for this material must be contained in a 13.7795" x 15.748" x 15.748" cube, and I'm sure the mask isn't bigger than that (unless the ears cause a problem).
As for price, its $2.50/cm³, but this applies for the total amount of MATERIAL used, NOT dimension of the object.
Since we see the mask being put on as a helmet, I don't see it being one-piece as a problem, and I'm sure it can be spray-painted black.
As for an update of the status of this, I have contacted the people on the Shapeways boards and this is doable; even using the slightly flexible, cheaper material may be possible depending on the size of the mask (And that depends on the person's head). I have acquired a 3D model that is about 85-90% accurate to the TDK version in 3DSMAX (which fits inside the aformentioned cube), but it needs a lot of tweaking, so I'll prob start from scratch and use it as a reference. I have plenty of reference photos as well, so all I need is some free time to really get into the modeling.
As far as fabrication goes, if anyone wants to pitch in on this, the design can be shard on Shapeways so anyone can order one, but like I said the size might differ based on head size, so perhaps an option S/M/L 3D models can be made to accomodate this.
I'll post some renders of what I have later on. If anyone is interested in helping out, let me know.