Bo Katan 3D Printed Bo Katan / Night Owl Build.

aprilstorm

Jr Hunter
Hi,

I started this thread over on the mando mercs forum, but seeing that there seem to be a lot of people interested in making a Bo Katan costume here that I would cross post some of my progress. http://mercs.firespray.net/forum/index.php?topic=60261.msg880508#msg880508

I am on a mission to 3D print all but the helmet, backplate and jetpack for my Bo Katan, and I will make the models free to download for anyone else who has access to a capable 3D printer (or friend with)

Im doing this primarily because I want the armor to fit my body correctly as I am a plus size girl.

All my designs will be uploaded to the thingiverse: About AprilStorm - Thingiverse you are free to download and print, derive, copy my designs licensed under the Attribution - Non-Commercial - Creative Commons license.

I started with gauntlets, because members of my clan in Melbourne Australia needed gauntlets more than anything else so Im printing a small number for them at the same time

Right Gaunt Reference:
LeftGauntlet.jpg

Note there is no visible seam on the outer side:
Star.Wars.The.Clone.Wars.S05E16.HDTV.x264-2HD.mp4_snapshot_14.55_%255B2013.02.04_21.55.41%255D.jpg


Right Gaunt Model, I oriented the opening so that it took no more than 50 degrees so it will not be visible on the outer, and rather than rely on fiddly piano hinges or velcro, I designed the latch to be printed into the gauntlet.

Fullscreen%2520capture%252012022013%2520110316%2520PM.bmp.jpg


First printed prototype:
P1090541.jpg


The door closes flush, and because its printed in ABS, the clip actually works to lock in the side as it looks like it should.
P1090544.jpg
P1090543.jpg


Left Gaunt Reference:

%2520HDTV%2520S05E15%25201080p%2520AVCHD-SC-SDH.mkv_snapshot_16.40_%255B2013.02.17_09.33.40%255D.jpg
%2520HDTV%2520S05E16%25201080p%2520AVCHD-SC-SDH.mkv_snapshot_14.33_%255B2013.02.17_10.04.26%255D.jpg


3D Model:

Fullscreen%2520capture%252017022013%2520110424%2520AM.bmp.jpg


Printing the missiles proved a bit challenging but still doable:

P1090545.jpg


Then it was a case of sanding off the print lines and painting, because they are printed in grey/silver abs, this made weathering much easier:

IMG_0073.jpg

I have made it so the knife will retract, but have left this to be manual rather than spring loaded as to keep with our requirements.
IMG_0070.jpg


Personally think the nozzles are a tad to big, but I can just scale it down the next time I print
IMG_0072.jpg

I still have to design and print the disc things that sit on her right hand gauntlet.
IMG_0074.jpg


- - - Updated - - -

the knees:

Reference Picture. note the squareness of the "ears"
BoKatanDetail-SWE%2520-%2520Copy.jpg


This is the model I made to represent the screen used knees, I have decided to print removeable "buckles" that slide into the knees. This will eliminate the need to use velcro or other attachments. An elastic belt can be sewn in and slide through button wholes in the flight suit.

Fullscreen%2520capture%252025022013%252095544%2520PM.bmp.jpg


This was the first prototype I printed:

IMG_0101.jpg


IMG_0070.JPG
 
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Wow! What an amazing build so far! I really love the way you did all the working elements and the greeblies. And all the files are (will be) available for free! I already see a lot of happy Bo Katans. Keep the great updates coming!
 
Those look great. What program did you use to make the files?
 
Your doing a great job on this. Im not a huge fan of animated real world stuff, but very nice craftsmanship here though. Id like to see real world interpritation of the Bo Katan.
 
Thanks for the feedback guys, Im actually finding this very rewarding and learning a lot along the way. When I started I had never used a CAD package before.

Ash, Im taking my time and just enjoying the build, Its going to take me to the end of the year I think before its completely finished and Im happy with it. Also, there is no way Im going to use a leotard as a flight suit, so not sure how that will go with approval for the clubs, as I am in the process of making a regular, be it more fitted version using a poly blend so it has some stretch but is not skin tight. What I hope to do is get the suit material dye sublimation printed from the graphics found in the media so it matches more closely.
 
These are BEAUTIFUL!!! What 3D Printer are you using??? I am looking into purchasing one, with my goal first-project being the shell of a Boushh Thermal Detonator. You are doing GREAT WORK!!!
 
I have a MendelMax 1.5 its now been replaced by the MendelMax 2.0 which has a much bigger build platform.

RepRap 3D Printer Kits - Maker's Tool Works

this is my printer: Hello Thingy, my Mendelmax printer build

Go over to the RepRap forums if you want more info on getting a printer, dont just impulse buy. You need to be able to print in ABS (PLA isnt really any good for things like this IMHO) so a nozzle no smaller than 0.4mm (if your using 3mm filament), and a heatbed is required.

Im running with a 0.5mm nozzle and use 3mm ABS filament which is very cheap to run, those gauntlets probably used about $25 of plastic to print, they just take their sweet time to do so.


Also for those living in the Midwest, there is a first RepRap festival : Midwest Reprap Festival | Home in March. Probably a great place to learn about printers and stuff. I'd be there if I didnt live on the other side of the planet.
 
I have been trying to source transparent Red ABS filament to print buttons that light up for these gauntlets with no luck, but found a work around.

IMG_0106.jpg


Apparently all you need is transparent filament, and using a sharpie, color it in before its fed into the extruder and melted. The ink from the sharpie will then blend into the plastic giving, in my case, a transparent red plastic needed for the red buttons.

IMG_0105.jpg


I got a chaser circuit from ebay and the spaces you see in the buttons are design to hold the LEDs on the inside of the gauntlet. The chaser has multiple program modes including one where the main white and red remain on and the others randomise.

IMG_0119.jpg


I think it turned out pretty good.

IMG_0120.jpg
 
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