Chappie 1:1 scale head replica

Discussion in 'Replica Props' started by Wupsje, Jun 18, 2015.

  1. Wupsje

    Wupsje New Member

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    Hi guys,

    I'm new on this forum.
    I have posted this in the Chappie discussion as well, but I thought I would make a new thread so I can
    update and show the progress on my 1:1 scale Chappie head.

    I'm currently busy with modeling his head in 3D:

    Chappie modelling 1.JPG Chappie modelling 2.JPG

    This is a work in progress, so nothing is realy final yet.
    Only the top lid of his head, which I have already 3D printed and I am currently filling and sanding it.
    I will show pictures here as I go along with the modeling and build process to keep you guys updated.
    If you have any suggestions or comments I would like to hear them so I can get my build as accurate as possible,
    because I might miss something.

    If you have any questions do not hesitate to ask me.

    Grtz,
     
    Sean likes this.
  2. Mike J.

    Mike J. Master Member RPF PREMIUM MEMBER

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    Awesome!

    I took a look through my references, and it looks like there's a small 'lip' where the top of the head meets the 'eye box.'

    I'm very impressed by your attention to detail – I never noticed that triangular indentation on the side of the eyes before.

    I hope these pics help :) It's hard to find good pics of the head without the 'eyebrow bar.'


    -MJ
     

    Attached Files:

    Sean likes this.
  3. Wupsje

    Wupsje New Member

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    Thanx a lot for these amazing reference images, I can definitely use these for perfecting my model further!
    I will post more pictures of my 3D model and printed parts as soon as possible.
     
  4. zorg

    zorg Master Member RPF PREMIUM MEMBER

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    so you can 3d model but you take a photo of the screen.

    i can take a screen cap but cant 3d model :p

    nice work on the head :thumbsup

    -z
     
    Sean likes this.
  5. Wupsje

    Wupsje New Member

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    I can take a screen cap :), but I was working on a different computer (work) that does not have screencap software, and I cannot install it there.
    Here's some more progress done:
    2015-06-19 17_05_52-Solid Edge ST5 - Assembly - [Chappie V02.asm].jpg
     
    Sean likes this.
  6. Wupsje

    Wupsje New Member

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    I have started 3D printing the parts that will not need more changes.
    And started filling and sanding them to get a smooth surface and getting rid of the 3d printed layers.
    Here are the parts so far inside my home-build spray cabin:

    IMG_5403.JPG

    Top of his head (lid)
    Eye bar and right side bolt for the eyebar. (needs some repair filling and sanding still)
    Side head cover - I will mould and cast this one to copy for both sides. (Saves me a lot of filling and sanding)

    More parts will be coming off my printer and I will keep filling and sanding them.
    If anyone would like a copy of the parts I can mould them and make resin casts.
    Please let me know if you are interested in building a Chappie yourself, of course we will need to negotiate a price
    for the parts and shipping.

    Grtz,
     
    Sean likes this.
  7. Mike J.

    Mike J. Master Member RPF PREMIUM MEMBER

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    Woo hoo!


    -MJ
     
  8. Sean

    Sean Sr Member RPF PREMIUM MEMBER

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    I'm liking this very much. just watched the film last week and thought it was wonderful. looking foreword to more on this....:thumbsup
     
  9. zookone

    zookone Well-Known Member

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    Looking great!
     
  10. Guardian Devil

    Guardian Devil Sr Member

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    I love it. Can't wait to see more!
     
  11. skillsthebarber

    skillsthebarber New Member

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    is this something you plan to wear or will it be a display piece?
     
  12. Halliwax

    Halliwax Legendary Member RPF PREMIUM MEMBER

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    this is great! i loved the movie. i can't wait to see this done!
     
  13. Wupsje

    Wupsje New Member

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    Thank you all very much for your kind words!
    For everyone who is wondering; this is going to be a just a display piece.
    Because of the accuracy to the real one, there will be no room to stick your head in.

    All parts will be made separate and there is room and possibility to animate him using
    servo's and arduino board(s) in the future. his eyebrows, ears and mouth have enough
    space next to them to add servo's. This is not something I will do on this build.

    Pieces are gradually coming off the 3D printer, I have finished modeling his ears, just a couple
    of things left to draw:

    2015-06-21 17_17_42-Solid Edge ST5 - Assembly - [Chappie V02.asm].jpg

    - Thingie for screw on his eye block.
    - The tube from his mouth bar back.
    - The back of his head (with all the parts and pieces).
    - His camera pod underneath his chin.
    -The couplings for the tubes on the sides of his neck.

    IMG_5404.jpg

    I'm printing the parts in PLA at 0,1mm resolution in Z and this works fine, just a little sanding required and some spray-filling.
    Currently the big part on the right side of his head is printing, this is a ~ 6 hour print.
    And of course I need the absolute accurate paint color.

    If anyone has an idea on what RAL color to use?
    And is this paint metallic paint or not? what's your opinion?

    Thanx,
     
  14. Mike J.

    Mike J. Master Member RPF PREMIUM MEMBER

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    Here are some ears, for reference.

    I think the color is metallic, though I'm not sure what to call it. To me, it looks somewhere between royal blue and navy blue, and gray.


    -MJ
     

    Attached Files:

  15. Wupsje

    Wupsje New Member

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    Mike, thanks again for the amazing reference images.!
    It looks a little like Hammerite paint what's on there.. but I don't think that comes in that exact color.
    Or I will need to mix it.

    The color looks like RAL 5000 / 5001 but that is hard to see via a monitor.
    I will need to do some shopping and see it with my own eyes what colors are available and match him.
    There has been a lot of debate on costume/prop colors as in movies it sometimes is really hard to tell,
    some scenes are by daylight others at night, a lot of filtering is done on the camera's and in the final footage.

    I have a lot of reference images from the movie, but I don't think he is exactly the same
    color in any of the scenes, so in the end it is all on; if the color feels right I guess?

    Grtz,
     
  16. Wupsje

    Wupsje New Member

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    Hi, here's an update again,

    I'm almost finished with modeling the 3D model, last part is only the stuff on the back of his head.
    The ears were a real pain in the *, I modeled them and after printing them I realized they were a bit small.
    After constantly superimposing my 3D model over a screen shot of the movie, I finally got
    the dimensions right and they only need some minor tweaking :

    2015-06-28 14_11_11-Solid Edge ST5 - Assembly - [Chappie V02.asm].jpg

    More pieces came off my printer and I'm well on my way with filling and sanding them.
    Yes, the ear in the picture is the one that was too small:
    IMG_0296 (2).jpg
    I have gathered some sample colors from the local hardware store, and I will keep looking
    to find the right color. So far I have not fount the absolute winner yet.


    Color reference.jpg
     
    Sean likes this.
  17. Halliwax

    Halliwax Legendary Member RPF PREMIUM MEMBER

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    great progress!
     
  18. zorg

    zorg Master Member RPF PREMIUM MEMBER

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    really nice work,

    not watched the film but i'm a sucker for robot heads.

    -z
     
  19. VanguardForge

    VanguardForge New Member

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    Very cool, looking forward to seeing it all put together.
     
  20. GaryArm

    GaryArm Member

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    I've just seen Chappie and wow this looks like a great project.
    When you have done the head, are you going to follow up with the rest of him?
    I would realy like to see that
     
  21. PBraddock

    PBraddock Active Member

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    Nice work! I love the Chappie design. What are you modeling in?
     
  22. Radical Gordon

    Radical Gordon New Member

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    This is amazing, excellent work.
    I look forward to seeing it finished.
     
  23. caxack

    caxack New Member

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    Great work on the head.

    I am currently building a Chappie from the movie for Costume for a Charity and have a whole bunch of bits (alot of what is in the Chappie Resource thread - the pics from ebay) however there are a few bits on the head I dont have and would like to be able to get a copy of the print file if possible or some to model the bits, so I can complete Chappie, they are:

    1. the camera pod
    2. the eye screen, and the
    3. lower tubes on the side of the head.

    I can provide measurements on any of the head peices I have if that helps. I have attached a couple of images, hope they help.

    IMG_2194.jpg IMG_2192.jpg IMG_2193.jpg
     
  24. Wupsje

    Wupsje New Member

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    Hi all, here's another update on my build.

    Let me start off by thanking caxack for the amazing references with measurements.
    Turns out I'm only off by 5mm (0.197 inch) just by eyeballing the measurement of the lid..not bad if I say so myself.
    But I see it has 7 holes, and mine 6..crap.. well too much to rework in this stage, I'll just have to leave it like this.
    IMG_5428 (2).jpg
    The ear is better to scale;
    IMG_5430 (2).jpg IMG_5431 (2).jpg

    I have finished modeling his CPU box and GPS box on the back of his head:
    2015-07-15 21_06_48-Solid Edge ST5 - Assembly - [Chappie V02.asm].jpg
    The hole for the fan is a tiny bit too big, but it fits an actual fan I have lying around.
    Printing is going great, all dark gray parts in the 3D model have been printed:
    2015-07-15 21_07_23-Solid Edge ST5 - Assembly - [Chappie V02.asm].jpg IMG_5429 (2).jpg

    So as you can all see I am getting along, it is not going super super fast, but I'm really trying to take
    the time to rework all the parts by filling and sanding them.
    This week my order of itsy bitsy screws should arrive too.
    O, I am modeling in Solid Edge for the curious ones ;-)

    Hope I can send you all an update soon where the main structure of his head is printed, that's when
    everything will start to come together.

    Cheerio,
     
  25. Mike J.

    Mike J. Master Member RPF PREMIUM MEMBER

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    Congratulations on your accuracy and progress :)

    How are you planning on executing the decals & markings on the head?


    -MJ
     
  26. caxack

    caxack New Member

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    A couple more pics that may help. These are the hose connections on the side of his head, I can supply measurements as well if you need them. Hose Connection 1.jpg Hose Connection 2.jpg

    Cheers
    Caxack
     
  27. joberg

    joberg Master Member

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    Great build so far Wupsje...and TFS these measurements with us caxack:cool
     
  28. lovelyandy

    lovelyandy Well-Known Member

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    oh my goodness. amazing work. so jealous.
     
  29. Wupsje

    Wupsje New Member

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    Itsy bitsy update;

    I've printed the main structure of Chappies head and I can start fit things together.
    Nothing is really fastened yet as I still need to make moulds.

    Rough assembly.jpg

    But as you can see, it all fits together so far.
    Next week I'm not able to do anything on him, but as soon as I have new parts or moulds
    I will keep you all posted.

    Grtz,
     
  30. OzJames

    OzJames New Member

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    Looks great. I saw this movie recently and really enjoyed it. Cant wait to see this finished. Keep up the good work.
     
  31. BlindSquirrel

    BlindSquirrel Sr Member RPF PREMIUM MEMBER

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    Wow! He's really looking great! I am super excited to see this come along!
     
  32. Mike J.

    Mike J. Master Member RPF PREMIUM MEMBER

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    Looking good!
     
  33. trooperprop

    trooperprop Well-Known Member

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    Looking really good! Loved the movie.
    just make it a whole figure:)

    greetings from the netherlands,

    basD
     
  34. Sean

    Sean Sr Member RPF PREMIUM MEMBER

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    WOW! that's Awesome!
     
  35. joberg

    joberg Master Member

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    Awesome indeed!
     
  36. EdsJunk

    EdsJunk Active Member

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    Is this going to be a 3D model you will share? I just watched the movie and wanted to do the same thing. Absolutely great work sir!
     
  37. PeterLC

    PeterLC Sr Member RPF PREMIUM MEMBER

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    Some people go for how the colour looks on screen while others like to go with the actual colours things were painted. Personally I like the actual colours used for stuff unless one is doing a representation of something.


     
  38. ebswift

    ebswift Member RPF PREMIUM MEMBER

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    Very nice, detailed work!

    Maybe a bit late, but I've done some 3D print smoothing. If you can print in ABS you can use the acetone vapour process, there are videos on youtube (apparently won't work on PLA). I've done a few pieces and they look injection moulded, no sign of layers and no loss of detail. In my process I bring it all to the boil first in a big beaker and get the cloud to the level that will cover the model, then drop it in, hanging from the top above the liquid, immersed in the cloud. I've only tried it for maybe 40 seconds when it almost starts dripping. Others talk about several minutes. Anyway, late, but thought I'd chime on on the layer smoothing FWIW...
     
  39. Taff83

    Taff83 Sr Member

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    Amazing work! Loved the film and think your doing a great job! I have to ask.. Will you be doing a run of the helmets or making them available to print or sell via the likes of shapeways? I'd be very interested if you were
     
  40. Wupsje

    Wupsje New Member

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    Hi, I know about acetone vapor smoothing, I have chosen for this method for a couple of reasons:

    1) ABS warps like a mother and is hard to print large objects straight, bend edges, cracks etc... ABS is not my thing at all and I avoid it whenever possible!
    2) My mancave is not so big, so the fumes would drive me away, especially because the printer is running almost 24/7 to complete this project.
    3) With acetone vapor, the whole look is going to be "melted" as the acetone will eat away all sharp edges and little details.

    These are the reasons why I have chosen for spray filler and sanding. It is a bit more work, but the finish is way better. ;-)
    But thanks for sharing anyway.. when it comes to 3D printing I have enough experience as I'm working for a company which designs and builds 3D printers.
    I'm a designer in the R&D department. ;)

    Grtz,
     
  41. Wupsje

    Wupsje New Member

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    For people who are wondering if they can get their hands on a 1:1 scale Chappie head; yes.

    I'm going to make molds and duplicate the parts in PU resin. You can get a do-it-yourself kit with all the parts in it.
    You will only need to clean-up (mold flash etc.), assemble and paint him. You might need to add some stuff yourself like the gauze on his eyes and
    mouth parts, as well as some LED's but it will be a complete set.

    The molds might take a while for me to complete, so please have a little patience.
    This is my first large scale project that needs duplication, but the silicone and PU resin has already arrived.
     
    Howlrunner likes this.
  42. Cyberman

    Cyberman Sr Member RPF PREMIUM MEMBER

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    Very cool :thumbsup
     
  43. ebswift

    ebswift Member RPF PREMIUM MEMBER

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    LOL, well I certainly underestimated your experience, maybe someone else will pick up on the info though. I didn't actually find a melted look, I was able to retain sharp edges with pretty much no sign of the original layering. Using a Dimension Elite which layers pretty fine.

    Thanks for the info with ABS though, I'm not up there with all the printing materials properties. Warpage mitigation could be something we can look at with our cheaper printers by exploring different materials. Pretty sure we're using ABS on the cheapies.

    Anyway, cheers and thanks for sharing your knowledge! :)
     
  44. Tuckanator

    Tuckanator Active Member

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    Looking very cool!
     
  45. EdsJunk

    EdsJunk Active Member

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    Any chance of sharing the 3D files?

    Sent from my SAMSUNG-SM-N920A using Tapatalk
     
  46. zapwizard

    zapwizard Sr Member RPF PREMIUM MEMBER

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    Nice CAD model. I see you're using Solid Edge. For future reference, you can easily get a screen grab by using the built-in "Save as > Save as an image" function.
     
  47. Wupsje

    Wupsje New Member

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    Hi all,

    sorry for the delay, I had to get my drivers license, my girlfriend is pregnant and we are planning on getting married
    this year as well.. so a lot of personal stuff going on and Chappie kind of got on the back burner for a while. Sorry.

    But today I moved on a little by finishing my little vacuum chamber:
    IMG_6070.JPG
    The bottom plate is glued and needs to dry before I can start her up.
    I also started on making some little parts ready for casting:
    IMG_6069.JPG
    So hopefully I can test my chamber and start making some molds this week. (I have a very busy schedule)


    Grtz,
     
  48. EdsJunk

    EdsJunk Active Member

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    Cant wait

    Sent from my SAMSUNG-SM-N920A using Tapatalk
     
  49. BlindSquirrel

    BlindSquirrel Sr Member RPF PREMIUM MEMBER

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    Great news!! I am totally looking forward to buying a kit!
     
  50. AmazonChitlin

    AmazonChitlin Active Member RPF PREMIUM MEMBER

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    Can't wait to buy a kit also!! Outstanding!

    Sent from my SM-G920V using Tapatalk
     

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