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  1. Member Since
    May 2014
    Posts
    23
    Aug 8, 2014, 4:43 PM - 3D Printing Mando Helmet #1

    Taking a break from my first scratch build because we got a new 3D printer at work and I thought...."I wonder"

    Sure enough, there was a plan for a Boba bucket on grabcad.com. I had to cut the dome off and print it separately because it was too tall for the printer. It's also a little angular, but that's ok because I will fiberglass and bondo it to strengthen and smooth it anyway.

    The dome took 15 hours and the bottom part is still printing (20 hours in at this point) and has about 10 hours to go...so it's an exercise in patience

    Anyway...here are some pics so far:

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    Dome (15 hrs to print)

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    face mask at 15 hours

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    face mask at 20 hours


    Like I said...about 10 hours to go and then I'll test fit them together and go from there. First time doing this so keeping my fingers crossed
  2. Member Since
    Aug 2014
    Posts
    1
    Aug 11, 2014, 2:27 PM - Re: 3D Printing Mando Helmet #2

    Cant wait to see the results, I just downloaded that grabcad file and plan on printing when I get back to school
  3. Member Since
    Apr 2013
    Posts
    67
    Aug 13, 2014, 6:32 AM - Re: 3D Printing Mando Helmet #3

    duuuuuude!!!!!!
    that is sick.....i want a 3d printer now!
    keep it up!
    -Ghost
  4. Member Since
    May 2014
    Posts
    23
    Aug 18, 2014, 11:32 AM - Re: 3D Printing Mando Helmet #4

    Finally finished! The helmet had to be sliced off in the 3D file as mentioned above, so it needs to be reattached (it sits low in the pics) But all in all a great skeleton! Next is the fiberglass/bondo stage. Also tried printing the earcaps but they are not flat on the bottom and do not print well. Had one that might be passable, and would have been fine if they had been printed with the helmet, but it would not have fit on the bed with them on I'll probably make some or order some resin ones. Anyway...here is the final print...

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  5. Member Since
    Jun 2012
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    184
    Sep 2, 2014, 1:36 PM - Re: 3D Printing Mando Helmet #5

    Have you tried printing the ear caps in 2pc? So it it will fit the curvature of the helmet?
  6. Member Since
    May 2014
    Posts
    23
    Sep 16, 2014, 5:55 PM - Re: 3D Printing Mando Helmet #6

    Hey sorry for the late reply. Yes I tried printing the ear caps but since they are curved they do not turn out well not matter how I try to rotate them in the modeler. In the market for some resin caps.
  7. jendor's Avatar
    Member Since
    Aug 2008
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    49
    Sep 17, 2014, 9:50 AM - Re: 3D Printing Mando Helmet #7

    Quote lerxstrulz said: View Post
    Hey sorry for the late reply. Yes I tried printing the ear caps but since they are curved they do not turn out well not matter how I try to rotate them in the modeler. In the market for some resin caps.
    i think what he meant was have you tried running a slice through the center plane and printing them as 2 halves i.e outer and inner (which as a result would both have Flat Bottoms that could be glued together
  8. Member Since
    May 2014
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    23
    Sep 18, 2014, 7:26 AM - Re: 3D Printing Mando Helmet #8

    Quote jendor said: View Post
    i think what he meant was have you tried running a slice through the center plane and printing them as 2 halves i.e outer and inner (which as a result would both have Flat Bottoms that could be glued together
    Ah...yes I did, but not it than way. The earcap with the stalk is the tricky one. Here are some pics of the first try of the left earcap...I printed it upside down since that was the flat surface, but the angle was a little rough. I will try slicing it along the lateral plane...that should work better...thanks for the idea!

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  9. Member Since
    Sep 2014
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    1
    Sep 19, 2014, 11:38 AM - Re: 3D Printing Mando Helmet #9

    How much filament did the entire helmet use?
  10. I helped at SDCC '08 NovallTalon's Avatar
    Member Since
    Feb 2007
    Posts
    2,032
    Sep 23, 2014, 10:10 AM - Re: 3D Printing Mando Helmet #10

    You shouldn't have that kind of trouble printing out a curved surface, what type of printer are you using? Alsoyou try printing it using supports and see if that helps, I've found that non-flat surfaces sometimes come out better when you add supports.
  11. Member Since
    May 2014
    Posts
    23
    Sep 23, 2014, 2:17 PM - Re: 3D Printing Mando Helmet #11

    It was around 3/4 of a spool for everything... not sure of the entire length... that should be in the slicer files. I'll take a look when I'm back from vacation :-)

    - - - Updated - - -

    Using a Lulzbot Taz printer... by no means an expert at this yet, but starting to figure out different ways to get stuff done :-) Thanks for the tip! Haven't had a chance to touch this project in a week so anxious to get back at it!
  12. Member Since
    Jun 2014
    Posts
    7
    Sep 25, 2014, 9:08 AM - Re: 3D Printing Mando Helmet #12

    So jealous, 3D printers keep getting more reasonable in price, I cannot wait to get one.
  13. Member Since
    Sep 2014
    Posts
    5
    Sep 29, 2014, 1:04 PM - Re: 3D Printing Mando Helmet #13

    How much does the printed helmet weigh?
  14. Member Since
    May 2014
    Posts
    23
    Sep 29, 2014, 5:05 PM - Re: 3D Printing Mando Helmet #14

    Quote Narcil said: View Post
    So jealous, 3D printers keep getting more reasonable in price, I cannot wait to get one.
    Yeah the Taz 4 we are using now comes as a kit, which will save you a lot...still not cheap but one of the better mid-range printers IMO: https://www.lulzbot.com/

    - - - Updated - - -

    Quote Neuromancer said: View Post
    How much does the printed helmet weigh?
    It's actually pretty light...MAYBE a US pound? I used PLA plastic which is a little more rigid. About to start the fiberglassing process but will see if I can get a weight beforehand. I have a scratch build going as well using 2mm cardboard and I would say that weights more than the 3D print so far.
  15. Member Since
    Sep 2014
    Posts
    1
    Sep 30, 2014, 12:15 AM - Re: 3D Printing Mando Helmet #15

    This is awesome! I would love to have a 3D printer!
  16. Member Since
    May 2014
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    23
    Oct 22, 2014, 10:46 AM - Re: 3D Printing Mando Helmet #16

    In my search for "the" helmet, I ordered one from Headshot Props to work on in conjunction with the 3D printed one. When I opened the box I thought it was a child's helmet lol. Then I realized that the 3D helmet is too big. The HSP helmet actually could stand a couple more cm, but it fits pretty well and I think I can get my electronics in there. I took a side-by-side shot of the two helmets and you can see that the 3D printed helmet is much larger. Around 33cm across (ear-to-ear) when from what I can tell the "official" measurement at that spot should be 26cm. I'm going to finish out the helmet because I love the project, but I will resize the 3D files to get closer to original. That's the great thing about 3D printing

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