Mjolnir Mark VII Build Thread - Halo Infinite


Off Earth

Member
Project Mjolnir Mark VII Gen 3

Good Evening from the Midwest!!! I’m Darryl (offearth3d). I’m currently working on my second Halo Armor build the Mjolnir Mark VII Gen 3 from Halo Infinite.

Unlike most builds I’m working on developing a more durable and flexible suit for the wearer (me). The entire armor at some stage will be cast in either Urethane Rubber or Plastic. I estimate somewhere along the lines of 85% of the suit will be rubber of various shore hardness by completion.

So far, I’ve 3D Printed the Right arm components and am working on the left. I’m using 3D Files from The Maykr and TurboCharizard.
Helmet is by VEK3D which has yet to arrive as I’m having it SLA printed by a company in China to reduce the post processing.

Bookmark this, it’s going to get lengthy and I’ll be making some pretty graphics right go along with everything soon! Enjoy what’s here in the moment and I’m happy to answer any questions!
 

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Off Earth

Member
We have a successful first cast! The 70A Urethane Rubber is very stout! I wouldn't "Gasp" dropping this on concrete!
Pictured is the original 3d print, which is Resin, along with the mold (Smooth-on Mold Max 30). The Black Piece is the cast part using the Alumilite Flex 70 Urethane Rubber.

I also Included the "Technical Document" for this piece and will have them for all pieces that I make for this suit. I'm very excited to continue this build. Next on the agenda is molding the Right Forearm and Bicep. Having all 3 of these pieces will help me determine the weight of these parts and how well they interact together. Alongside that I'm waiting for some painting materials to get here so I can test out a method of painting Rubber and not having it crack, chip or flake off!
 

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Off Earth

Member
Spartan Daddy 069 - Reporting for Duty!
Project Mjolnir MK VII is well underway! Thanks to the_makyr and skookumprops for the amazing files!

Chest has been printed as well and will be the next part to get the sanding, polyester primer treatments. Hoping to have the full upper body ready for casting sometime in November!
 

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Off Earth

Member
Update:

Had a successful test pull of the Forearm. This was cast in Smoothon Smoothcast 65D (tinted). I'm probably going to remake the mold with Rebound 25 for a thicker mold that I can get several pulls from. The Final Casts will also be in Smoothon Task 15 because castings are rigid and durable, resist moisture, moderate heat, solvents and can be machined. So adding armor attachments or even something like button snaps would work without cracking or causing structural damage to the piece.

I've also started molding the right bicep as well. Soon that will be cast in Alumilite Flex 70, and we will have the right arm ready for some paint tests!
 

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Argent

Member
So, how will you end up putting all this together? I know most professional suits are cast like this, but to my knowledge they usually have a form fitting molded undersuit underneath to keep all the weight in place. Are you planning on doing that, or just a really robust suspension system?
 

Off Earth

Member
So, how will you end up putting all this together? I know most professional suits are cast like this, but to my knowledge they usually have a form fitting molded undersuit underneath to keep all the weight in place. Are you planning on doing that, or just a really robust suspension system?
I have a lycra bodysuit that I will be attaching urethane rubber pieces to for the undersuit. Various areas will be rigged for attaching armor as well.
 

Off Earth

Member
Update Mobility/Flexibility Test:

This morning I was able to demold the right bicep and test out the fit and flex of it alongside the right forearm. I've attached a video from my YouTube Channel (short) demonstrating how the rubber bicep and rigid forearm interact with each other. I think you'll be surprised with the results! The Bicep was cast with Alumilte Flex 70.

Mjolnir MK VII Flex Test
 

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Off Earth

Member
After 171hrs and 5KG of PETG, The Torso section is complete!
Next steps here will be -
  • Sand down everything!!!!
  • Prime with Featherfill G2 (high build polyester primer)
  • Spot Fix Trouble Areas
  • Prep & Mold with Rebound 25
  • Cast Front and Back in Task 15
  • Cast Lower Straps in Flex 70 (urethane rubber)
Weather will be great this coming week so I plan on busting this piece out!!! I still need to order more mold making and casting materials... But that just means more time to focus on getting these parts ready! Then I'll have the whole upper body (minus the undersuit components)!
 

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Off Earth

Member
Been slow motion over here, but I did manage to get the abdominal wrap printed, and a more accurate neck seal (not pictured).

I’m also starting to receive some molding products. My silicone arrived today, which means I can start molding the left arm components!! Still waiting on resin and rubber to get here but there is plenty to do with what I have currently.

Lastly, my paint shed is being insulated and drywall hung. So a lot of effort will be going into this, converted to a full blown workshop! Stay Tuned.
 

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