Transhuman325
Active Member
Amazing work!! Subscribed!
3D Printed Functional Iron Man Mark III
- Thread starter TheRealStark
- Start date
TheRealStark
Well-Known Member
thanks Ryan!..
man this is coming along great! good job on those pcbs too!
Soon.. good things to come!
Yep... good things to come indeed.
Thanks so much!
Ha ha, thanks.
TheRealStark
Well-Known Member
Update on helmet:
In order to get into the helmet (and to stay true to the movie), I needed to make the back of the helmet "cascadable". So, I basically had to remodel the entire interior of my helmet design, and then had to separate it into three interconnected pieces.
I decided to make the "ear disc" actually serve a purpose, and so after a few creative modifications, it is now the driving force behind this collapsible mechanism. It is directly connected to the base section, and has a gap on the bottom side that will catch the second piece as it's rotated. Surprisingly, there is a lot of clearance between the three sections. The mechanism is virtually undiscernible from the exterior, and takes up no additional space inside.
Next step - add a catch for the middle section so it doesn't fall down further than it's supposed to, and then adding on the joints for the jaw and the hinge system for the mask.
In order to get into the helmet (and to stay true to the movie), I needed to make the back of the helmet "cascadable". So, I basically had to remodel the entire interior of my helmet design, and then had to separate it into three interconnected pieces.
I decided to make the "ear disc" actually serve a purpose, and so after a few creative modifications, it is now the driving force behind this collapsible mechanism. It is directly connected to the base section, and has a gap on the bottom side that will catch the second piece as it's rotated. Surprisingly, there is a lot of clearance between the three sections. The mechanism is virtually undiscernible from the exterior, and takes up no additional space inside.
Next step - add a catch for the middle section so it doesn't fall down further than it's supposed to, and then adding on the joints for the jaw and the hinge system for the mask.
ROBOSTEVE 0671
Sr Member
Wow Ryan, how the hell did I miss this thread!??? Subscribed
Most impressive
Most impressive
TheRealStark
Well-Known Member
Ha ha, thanks Steve! I don't know - but I'm happy you found it now!
TheRealStark
Well-Known Member
Thanks! Yes, Lego was (and still is great) for prototyping - it has allowed me to fine-tune all of the mechanisms I need to make this function, and it's very cheap (and FUN) to work with.
Thank goodness for 3D printers though! Now I can bring all of the ideas in my head to life!
PurdueMadLou
Member
Um, is this real? This can't be real. It's too f'ing cool to be real. Completely in awe.
TheRealStark
Well-Known Member
Ha ha, thanks. The engineer in me is non-existent, but my passion for this suit has driven me to teach myself what I need to know to make this possible.
And yeah - Lego is a lifelong toy for lifelong kids.
Ha ha, thanks! At the moment, it's still virtual, but I'm hoping to change that in the next few months!
PurdueMadLou
Member
I've watched all of your vids and read through most of your builds here and I'm actually not surprised you'd undertake such a monumental challenge. It's gonna be epic! Cheers to you. :cheers
PurdueMadLou
Member
I've watched all of your vids and read through most of your builds here and I'm actually not surprised you'd undertake such a monumental challenge. It's gonna be epic! Cheers to you. :cheers
TheRealStark
Well-Known Member
Thanks so much! Yep - here's hoping it all comes together!
Thanks so much! Yep - here's hoping it all comes together!
TheRealStark
Well-Known Member
Modelling with surfaces wasn't too bad actually. In total there are 128 surfaces in just the main part of the helmet. The jaw and mask probably have the same combined, so about 250 total? I can't really get a screen cap of my model tree because it extends so far down, lol (I have a lot of work surfaces intermixed, lol)
That's a lot of surfaces... Have you heard of Alias? I'm going to try the free trial at some point next week... it's meant exactly for that purpose, and it interacts well with Inventor - supposedly. The problem I had with surfaces is that sometimes, after a stitch, I'd get a wavy line between my surfaces, and wavy lines don't play well with extrusions.
TheRealStark
Well-Known Member
No, I haven't heard of Alias - let me know how it works for you. And, I haven't really had problems with the stitch surface function - it's done a pretty decent job of connecting everything as I intended. Granted, I haven't actually printed anything that I made from surfaces yet, so it'll be interesting to see how they turn out. Thanks for the info though!
TheRealStark
Well-Known Member
Helmet Update:
95% complete! I've now designed the eye lenses and the long-awaited mask movement mechanism.
Using the HS-125 Metal Gear servo, I designed an enclosure that connects two arms to the inside-top of the mask, and uses a two-point rotation system to raise and lower the mask. In the second image of just the hinge mechanism, you can see the "rotation-stop" piece, that prevents the mask from tilting down and obstructing your view when opened. The center bar that connects to the mask also has sections removed so that you can secure it with tape, as well as gluing it to the interior.
I decided on a "forehead tab"-mounted hinge system for four reasons:
1. Because there is the most clearance there, as opposed to the side of the head.
2. Servos mounted at the side of the helmet would be whirring in your ears and be very annoying.
3. Servos on the side of the helmet also require TWO servos, and therefore cost more.
4. This design can be transferred to any version of the IM helmet.
The only limitation to this design is that the HS 125MG servo has a 90 degree rotation limit, which means the mask cannot be set on top of the helmet. But, since this is the only drawback, it seemed like the best option for me.
In the image of the eye lens, I removed the white illumination so you can see the indentations that are designed to fit my new eye LED PCBs that use the same SMD LEDs I use in all of my projects. This design allows the lenses to be illuminated from the top, which prevents hotspots from behind, and takes up minimal space. The new boards support white or red LEDs for Iron Man and War Machine respectively.
The last part I need to do is create the hinges for the jaw. It will simply connect with a cable that then gets tied to one of the holes in the arms of the lift mechanism.
My 3D printer had to be sent back to NY again for repairs, but they've assured me it's good-to-go now, and should arrive in the next few days. As soon as it arrives, I'm going to be printing off a set of the mask hinge mechanism, and I'll post a video of it in action hopefully in the next week or two.
Let me know your thoughts!
95% complete! I've now designed the eye lenses and the long-awaited mask movement mechanism.
Using the HS-125 Metal Gear servo, I designed an enclosure that connects two arms to the inside-top of the mask, and uses a two-point rotation system to raise and lower the mask. In the second image of just the hinge mechanism, you can see the "rotation-stop" piece, that prevents the mask from tilting down and obstructing your view when opened. The center bar that connects to the mask also has sections removed so that you can secure it with tape, as well as gluing it to the interior.
I decided on a "forehead tab"-mounted hinge system for four reasons:
1. Because there is the most clearance there, as opposed to the side of the head.
2. Servos mounted at the side of the helmet would be whirring in your ears and be very annoying.
3. Servos on the side of the helmet also require TWO servos, and therefore cost more.
4. This design can be transferred to any version of the IM helmet.
The only limitation to this design is that the HS 125MG servo has a 90 degree rotation limit, which means the mask cannot be set on top of the helmet. But, since this is the only drawback, it seemed like the best option for me.
In the image of the eye lens, I removed the white illumination so you can see the indentations that are designed to fit my new eye LED PCBs that use the same SMD LEDs I use in all of my projects. This design allows the lenses to be illuminated from the top, which prevents hotspots from behind, and takes up minimal space. The new boards support white or red LEDs for Iron Man and War Machine respectively.
The last part I need to do is create the hinges for the jaw. It will simply connect with a cable that then gets tied to one of the holes in the arms of the lift mechanism.
My 3D printer had to be sent back to NY again for repairs, but they've assured me it's good-to-go now, and should arrive in the next few days. As soon as it arrives, I'm going to be printing off a set of the mask hinge mechanism, and I'll post a video of it in action hopefully in the next week or two.
Let me know your thoughts!
Surreal Studios
Well-Known Member
I am loving that hinge set up buddy! Great work as always!
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