3D Printed General Kael Masks UPDATE! Nov 8th! Prototypes Finished!

[Jennigirl]

This it a pet project of mine I started back in september with hopes of finishing it before the new Willow series.
Sadly it just sort of sat on a shelf as I got sidetracked with other things.
I finally decided to start working on it again.
It has already been modified from the original print to more closely resemble the screen used masks.
I am currently filling and sanding it smooth. Afterwards I plan to mold it and make fiberglass reinforced resin castings.
I also plan on taking one of the castings and making a battle damaged mask replica and make a mold of it as well.

 

[Jennigirl]

Update on this project!
Hoping to have it ready to mold by the end of the month. I will do a small run of raw kits, when everything is done.
I'll post another update when it's ready to be molded.

 

[Too Much Garlic]

Always liked this mask. Keep up the good work.

 

[Jennigirl]

Always liked this mask. Keep up the good work.

Thank you. Hopefully it will turn out well enough to do a small run of them.

 

[Jennigirl]

Attached rear jaw teeth.

 

[Jennigirl]

Almost ready to mold! The teeth are finished and ready to mold. Just need to sand down a few rough areas, and a few of the cracks in the filler/primer on the main mask.

 

[The Kaiser]

Love it! General Kael is one of my all-time favorites.

 

[Jennigirl]

Nearly ready! Waiting for the filler/primer to dry, then its time to mold.

 

[Jennigirl]

Finally ready for the molding process.

 

[Too Much Garlic]

Ooh... that turned out gnarly. What a cool sculpt.

 

[Jennigirl]

Ooh... that turned out gnarly. What a cool sculpt.

Thanks. Just redid the eyes today, to be more accurate.

 

[Jennigirl]

Looks like I'll be able to start the molding process either this afternoon, or tomorrow as the silicone thickener I ordered is out for delivery.
Just need to smooth out the clay around the mask. It is also my first time molding in silicone so wish me luck

 

[ISZA]

Looks like I'll be able to start the molding process either this afternoon, or tomorrow as the silicone thickener I ordered is out for delivery.
Just need to smooth out the clay around the mask. It is also my first time molding in silicone so wish me luck

Will you be doing a run and if so do you have a rough idea on price?

 

[Jennigirl]

Will you be doing a run and if so do you have a rough idea on price?

Yes. 150 for raw semi trimmed, and 250 for fully trimmed and painted. Im hoping to do 25 finished, and 25 raw

 

[Jennigirl]

LATEST UPDATE!
First test casting!
Not perfect, but it will clean up nicely!

 

[Jennigirl]

So I did a second casting the other day and the mold failed during demolding. The cast came out clean enough to reinforce and repair.
Unfortunately the mold is now unusable as it tore beyond repair. Mainly the nose section of the mold which tore off into several pieces.
I hope to eventually mold one of the cleaned up casts so I can continue making them.

 

[Michael Bergeron]

That sucks! 1000% interested in one of these should it get to that stage! I've always wanted this helmet!

 

[E Williams]

What a cool project and sorry about your mold!! Based on the purple color, did you use Smooth-on Oomoo silicone? You might look into something from the Mold Star family for your new mold. Oomoo tends to tear easily (and becomes more brittle with even a few months age), while Mold Star has a much higher strength and long library life.

 

[Jennigirl]

It was smooth on smooth sil 945 which may have been too stiff.

 

[Jennigirl]

Got the Battle damaged Mask partially trimmed today.