So newby here but I've gotten started on my ODST build. The plan is to work from the head down with a mix of 3D printed components, and EVA foam after getting some input from you guys here in another post. I have a friend who is taking provide files here on the 405th and ether running them through a slicer to 3D print, or other programs to make templates to foam craft.
We started with the helmet and decided to do it as a 3D print. After some turning and slicing, we found a way to reduce the supports needed as well as print the full helmet as one print. We started with a fresh roll of white PLA and got to work.
This was going fine until the printer broke. Lucky for us, the printer recognized it and an error and did a safety stop. The thermal sensor on the print bed died and triggered a safety stop to prevent a fire. But luckily my friend was able to find where the printer stopped, and after a quick repair get the print started where it left off. This does mean that the helm is in two parts.
This is the end result, with most of the supports still in place and a lot of clean up still to do. We both took a part and started to break off supports and clean up the prints.
After a few hours of clean up we noticed a happy accident. When the print was restarted, the second half was started a few steps back. So there is some overlap. This means I need to trim 1mm of material off the top half to get everything to line up right.
Next steps for the helmet:
1. More clean up and trimming
2. Bondo to fill some of the gaps and smooth out a few imperfections
3. Primer and paint
4. Foam inserts, strap, and fan
5. Visor. (We might make a vacuform machine for this, or I might try to source one from here. Don't know yet)
Pros so far. There is a level of detail that I just don't think I could have achieved with foam. Its also very lite. I ride motorcycle and my motorcycle helmet is heavier than this.
Cons. It took 10 days to print. It was an estimated 8 days, but the printer down time added to that. It was also a bit nerve racking knowing that it could fail. It did also take about 65% of a full roll of PLA.
The next big steps, things that will get worked on in a few weeks when life stops kicking my butt, print out paper templates for the main chest carrier so that can be made out of foam. While also printing the main large "trauma" chest plate on the 3D printer. I plan to have different elements of this going on at once, so while paint is drying we can work on foam. Or while DAP is curing on foam get paint on other parts done.
I'm supper stoked to not only be working on this but to have friends giving me a helping hand with this.
We started with the helmet and decided to do it as a 3D print. After some turning and slicing, we found a way to reduce the supports needed as well as print the full helmet as one print. We started with a fresh roll of white PLA and got to work.
This was going fine until the printer broke. Lucky for us, the printer recognized it and an error and did a safety stop. The thermal sensor on the print bed died and triggered a safety stop to prevent a fire. But luckily my friend was able to find where the printer stopped, and after a quick repair get the print started where it left off. This does mean that the helm is in two parts.
This is the end result, with most of the supports still in place and a lot of clean up still to do. We both took a part and started to break off supports and clean up the prints.
After a few hours of clean up we noticed a happy accident. When the print was restarted, the second half was started a few steps back. So there is some overlap. This means I need to trim 1mm of material off the top half to get everything to line up right.
Next steps for the helmet:
1. More clean up and trimming
2. Bondo to fill some of the gaps and smooth out a few imperfections
3. Primer and paint
4. Foam inserts, strap, and fan
5. Visor. (We might make a vacuform machine for this, or I might try to source one from here. Don't know yet)
Pros so far. There is a level of detail that I just don't think I could have achieved with foam. Its also very lite. I ride motorcycle and my motorcycle helmet is heavier than this.
Cons. It took 10 days to print. It was an estimated 8 days, but the printer down time added to that. It was also a bit nerve racking knowing that it could fail. It did also take about 65% of a full roll of PLA.
The next big steps, things that will get worked on in a few weeks when life stops kicking my butt, print out paper templates for the main chest carrier so that can be made out of foam. While also printing the main large "trauma" chest plate on the 3D printer. I plan to have different elements of this going on at once, so while paint is drying we can work on foam. Or while DAP is curing on foam get paint on other parts done.
I'm supper stoked to not only be working on this but to have friends giving me a helping hand with this.