Hey! So after a few months of figuring out the logistics of this, I'm finally in the design stage. I wanted to build a complete 3D prototype before starting the build, that way I can determine which pieces I can handle and which will need to be outsourced. First a bit of background:
DESIGN PHILOSOPHY
I'm sort of getting in over my head on this one (intentionally) so i'm likely going to need a lot of your expertise and guidance. This is a piece based on concept art, so I'm going to be taking some liberties with the details. As far as the construction, I want to get into a realistic level of detail in both appearance as well as materials and manufacturing. So not a replica of what may have been used on-set or a typical 'prop' piece, but something that looks, feels and operates like something pulled directly out of the universe it was designed for. Like those insane
graflex lightsaber replicas that go way beyond what was ever used for the film. We're gonna need a lot of different materials and processes. Fortunately I don't have to worry about tracking down original parts since this was never manufactured for the film.
CAD
I've had a bit of experience with several 3D modeling programs but I am completely new to CAD so I researched programs for a while. I finally landed on '
OnShape'. It's awesome. Completely browser & cloud-based, so no downloads. installs, or saves required. You can access your files with their iOS/Android app to view on any device. And most importantly, it it built for sharing and collaborating. Think of Google Docs, but for CAD. Best of all it's free if you register as a hobbyist. I'll be a sales rep for them in no time. Anyways, enough on them. It's a steep learning curve so it will take some time for me to get a handle on it but the design is underway.
Lastly, look at this. Maybe this has already talked about but I hadn't seen anything. In the particular concept I am referencing, after boosting the contrast of the source image I noticed some details of the helmet I had never noticed before. One is that there appears to be some artifacts around the mouth portion of the mask suggesting that this design did not incorporate (possibly) a full vizor.
Additionally, the vizor in the side view appears to be at a very different angle than the front of the mask, so it looks like the outer helmet is really a shell sitting on top of an inner-helmet or mask piece. The visor is recessed quite a ways from the front plate. Also that chin piece sitting below the helmet...
That got me sort of excited. Ok, more updates on the way. Thanks for checking in!