Hey joonbug1, adding thickness and modifying obj files for 3D printing can definitely be a challenge. Keep on tinkering and you'll get it. I'd advise that you always keep the original version saved so you can go back and try different things. Each piece will require different tweaks to make the model printable. After awhile, you'll be able to see those areas that will give you trouble ahead of time and you can have an idea of the tweaks you'll need to make.
Real Life kind of got in the way of me making any real progress over the weekend. I did get the jaw printed out. I cut it into two pieces and printed it that way. I'll get some pics and a video up soon.
Right now I'm trying to figure out how to modify the main part of the helmet so I can have the lower back portion of it move and rotate up instead of being removable. I want to have a second mode programmed into it that will be a "don/remove" mode, that makes it open and close like in this .GIF:
To do this, I need the back to rotate up and down, and I also need the ear cups to rotate and "screw" in and out. I want to print the helmet with all the proper joints, hinges, etc, so I won't have to do any serious modifications after printing. It's proving to be quite the challenge!
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if can pull all this off as a display maybe, wearable good luck... To bad in the movies its all digital...
