Fallout: 3D Printed Power Armor Helmets UPDATED 12/2/2018
- Thread starter GhostMinion
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GhostMinion
Sr Member
Re: Fallout 3: 3D Printed Power Armor Helmets
Thank you sir! But stick around, it gets better. Just received two gallons of silicone from Smooth On, and will begin making the mold for the Fallout 3 version of the T-51b lid this weekend,
At long last, the first helmet is almost here!!!
Thank you sir! But stick around, it gets better. Just received two gallons of silicone from Smooth On, and will begin making the mold for the Fallout 3 version of the T-51b lid this weekend,
At long last, the first helmet is almost here!!!
GhostMinion
Sr Member
Re: Fallout 3: 3D Printed Power Armor Helmets
Just finally finished things up on the main shell. I'm ready to start making the mold for this.
Just finally finished things up on the main shell. I'm ready to start making the mold for this.
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GhostMinion
Sr Member
Re: Fallout 3: 3D Printed Power Armor Helmets
Hey everybody. Been a while, eh?
So, some bad news I'm afraid. I think I'm finally ready to talk about it, so here goes.
So, the T-51b helmet that I made, in all it's glory, is no longer with us. To sum it up, I completely botched the mold making part. Seems like I did just about everything wrong that I could have.
I'd rather not go into specifics, as it's kind of embarrassing. But essentially, the helmet came apart into pieces when removing it from the "mold". The mold itself was no good, parts that were not cured and such. In a nutshell, total FUBAR.
As one might be able to imagine, that hurt. A lot. Something like that tends to take the wind out of you.
So, I needed to take the time to take a break, and walk away. This happened quite some time ago, yet only now does it start to not sting as much.
And so, with that, it's time to start picking myself back up and getting back to it. After all, Power Armor Helmets aren't going to build themselves. And with the new ones from Fallout 4, there's even more of them to make. So...............
Obviously, the T-51b helmet needs to be re printed. This, as before, is quite a task. Especially the way I do it, by that I mean printing the parts as absolutely big as possible for less cuts to repair. However, there are a couple benefits to a re print. This has allowed me to slightly alter the way the hoses will attach. Me and Cassius realized later on (from the point that he first modeled the T-51b helmet) that the way the hoses were set up to attach was not exactly the best method. The hoses would key into a shallow key slot on both ends, and the key was too shallow. You see, he can model them faster than I can print them, so this kind of knowledge didn't catch up to us until the second or third helmet. But now, we can change that. I myself have already deepened these key slots, but Cassius himself has come up with a much better way while designing the new T-60 helmet, in which the male end of the key arrangement is on the helmet, not the hose. I looks much sturdier, and might work better for rubber casted hoses. The original set up for this would have been better if we had planned the hoses to be hard plastic, like in a static prop, but this is not what I had in mind.
Aside from that, I opened up the entry hole at the rim of the helmet, so that my head will actually fit into it. The original set up was exactly like the game model, and the rim was way to small for my head to pass through. The plan was always to open these up manually once they were casted, but as one can imagine, this would be a lot of extra work. Changing this will save time down the road.
So, with the 3d model optimized a bit, I plan on re printing soon. I have a battery back up on order, and once I get that all set up I'll begin the printing. Some of these cuts will take up to 80 hours to complete, so I need assurance that the power going out (due to Maryland's very famous sudden thunderstorms) will not ruin the prints. I've rolled the dice in the past, not doing it anymore, though. Aside from that, I will be moving forward with many of the smaller parts that I already have.
In some of this "void time", I have worked a little on the T-45d helmet. Not like I've got much done or anything, but you gotta start sanding at some point, right? I plan to do quite a bit more with the T-45d print in the next couple weeks. After all, might as well be working on it while the new T-51b prints out. Why sit around twiddling thumbs. Anyhow, I'll hopefully have some pics of something worth showing soon with the T-45d.
Cassius is almost done modeling the T-60 helmet as we speak. The main shell and most of the parts are ready to print, with only a few parts left to model. It's only a matter of time now until the Atom Cats version of the helmet sits at my desk. It will be epic. More to come on that in the coming months.
I myself still need to finalize the model for the new version of the T-51 helmet (F4 version). I have not been modeling as much lately, as the change in weather lures me to the outside world. Not sure when I'll pick it back up, with so many other projects going on. I'll get to it eventually. Already accomplished too much on it to not finish.
So, there it is. Wish me luck. I may inquire about having a professional make the molds next time. However I've been doing a great bit of homework on brush on molds, and have been trying to absorb as much info as possible in the hopes that I might be able to do it myself. We'll see once we get there, which as it stands, will be after a good bit of work and a great bit of time.
Hey everybody. Been a while, eh?
So, some bad news I'm afraid. I think I'm finally ready to talk about it, so here goes.
So, the T-51b helmet that I made, in all it's glory, is no longer with us. To sum it up, I completely botched the mold making part. Seems like I did just about everything wrong that I could have.
I'd rather not go into specifics, as it's kind of embarrassing. But essentially, the helmet came apart into pieces when removing it from the "mold". The mold itself was no good, parts that were not cured and such. In a nutshell, total FUBAR.
As one might be able to imagine, that hurt. A lot. Something like that tends to take the wind out of you.
So, I needed to take the time to take a break, and walk away. This happened quite some time ago, yet only now does it start to not sting as much.
And so, with that, it's time to start picking myself back up and getting back to it. After all, Power Armor Helmets aren't going to build themselves. And with the new ones from Fallout 4, there's even more of them to make. So...............
Obviously, the T-51b helmet needs to be re printed. This, as before, is quite a task. Especially the way I do it, by that I mean printing the parts as absolutely big as possible for less cuts to repair. However, there are a couple benefits to a re print. This has allowed me to slightly alter the way the hoses will attach. Me and Cassius realized later on (from the point that he first modeled the T-51b helmet) that the way the hoses were set up to attach was not exactly the best method. The hoses would key into a shallow key slot on both ends, and the key was too shallow. You see, he can model them faster than I can print them, so this kind of knowledge didn't catch up to us until the second or third helmet. But now, we can change that. I myself have already deepened these key slots, but Cassius himself has come up with a much better way while designing the new T-60 helmet, in which the male end of the key arrangement is on the helmet, not the hose. I looks much sturdier, and might work better for rubber casted hoses. The original set up for this would have been better if we had planned the hoses to be hard plastic, like in a static prop, but this is not what I had in mind.
Aside from that, I opened up the entry hole at the rim of the helmet, so that my head will actually fit into it. The original set up was exactly like the game model, and the rim was way to small for my head to pass through. The plan was always to open these up manually once they were casted, but as one can imagine, this would be a lot of extra work. Changing this will save time down the road.
So, with the 3d model optimized a bit, I plan on re printing soon. I have a battery back up on order, and once I get that all set up I'll begin the printing. Some of these cuts will take up to 80 hours to complete, so I need assurance that the power going out (due to Maryland's very famous sudden thunderstorms) will not ruin the prints. I've rolled the dice in the past, not doing it anymore, though. Aside from that, I will be moving forward with many of the smaller parts that I already have.
In some of this "void time", I have worked a little on the T-45d helmet. Not like I've got much done or anything, but you gotta start sanding at some point, right? I plan to do quite a bit more with the T-45d print in the next couple weeks. After all, might as well be working on it while the new T-51b prints out. Why sit around twiddling thumbs. Anyhow, I'll hopefully have some pics of something worth showing soon with the T-45d.
Cassius is almost done modeling the T-60 helmet as we speak. The main shell and most of the parts are ready to print, with only a few parts left to model. It's only a matter of time now until the Atom Cats version of the helmet sits at my desk. It will be epic. More to come on that in the coming months.
I myself still need to finalize the model for the new version of the T-51 helmet (F4 version). I have not been modeling as much lately, as the change in weather lures me to the outside world. Not sure when I'll pick it back up, with so many other projects going on. I'll get to it eventually. Already accomplished too much on it to not finish.
So, there it is. Wish me luck. I may inquire about having a professional make the molds next time. However I've been doing a great bit of homework on brush on molds, and have been trying to absorb as much info as possible in the hopes that I might be able to do it myself. We'll see once we get there, which as it stands, will be after a good bit of work and a great bit of time.
Re: Fallout 3: 3D Printed Power Armor Helmets
I empathize completely. It sucks the big one, but in the end this whole journey is one big learning process, and now you have the chance to make something even better than before (thought it not possible!). Just hold onto and focus on that little spark of excitement you get when starting a project (I know we all get it). Good things will happen in the end
I empathize completely. It sucks the big one, but in the end this whole journey is one big learning process, and now you have the chance to make something even better than before (thought it not possible!). Just hold onto and focus on that little spark of excitement you get when starting a project (I know we all get it). Good things will happen in the end
GhostMinion
Sr Member
Re: Fallout 3: 3D Printed Power Armor Helmets
Thanks brother. :thumbsup I know you had to go through the same tragedy, it definitely does suck, but in the end we'll pull through.
After all, if it was easy, everyone would be making them.
I empathize completely. It sucks the big one, but in the end this whole journey is one big learning process, and now you have the chance to make something even better than before (thought it not possible!). Just hold onto and focus on that little spark of excitement you get when starting a project (I know we all get it). Good things will happen in the end
Thanks brother. :thumbsup I know you had to go through the same tragedy, it definitely does suck, but in the end we'll pull through.
After all, if it was easy, everyone would be making them.
RockIt
Active Member
Re: Fallout 3: 3D Printed Power Armor Helmets
Good luck man. Your stuff is always quality, and the hard thing about high standards is when you succeed, you couldn't be more happy! But when something happens and causes it to crash and burn, well.....the sting is uber-rough. Enjoy taking the break, re-focusing some, and clearing your mind. When you're ready to come back and double down, I'm pretty confident you'll avoid the same mistakes and end up w/a fantastic mold/cast.
Good luck bud
Good luck man. Your stuff is always quality, and the hard thing about high standards is when you succeed, you couldn't be more happy! But when something happens and causes it to crash and burn, well.....the sting is uber-rough. Enjoy taking the break, re-focusing some, and clearing your mind. When you're ready to come back and double down, I'm pretty confident you'll avoid the same mistakes and end up w/a fantastic mold/cast.
Good luck bud
GhostMinion
Sr Member
Re: Fallout 3: 3D Printed Power Armor Helmets
Sorry for the lack of updates. Been taking a bit of a break, but it's time to get back to business. Here's the start of the new T-51b helmet print. The original helmet was cut into five sections, basically because of software limitations. This go around we'll be doing it in three sections, exactly like I printed the T-45d helmet. Less seams to fix should help speed up the mastering process, if only a little. Anyhow, more to come soon.
Will also have some nice pics of the T-45d progress real soon. Stay tuned.........
Sorry for the lack of updates. Been taking a bit of a break, but it's time to get back to business. Here's the start of the new T-51b helmet print. The original helmet was cut into five sections, basically because of software limitations. This go around we'll be doing it in three sections, exactly like I printed the T-45d helmet. Less seams to fix should help speed up the mastering process, if only a little. Anyhow, more to come soon.
Will also have some nice pics of the T-45d progress real soon. Stay tuned.........
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Re: Fallout 3: 3D Printed Power Armor Helmets
Glad to see you back at it! I think it will be easier this time because you know a little more and what to expect :thumbsup
Glad to see you back at it! I think it will be easier this time because you know a little more and what to expect :thumbsup
OBI WAN KEN0B1
Sr Member
Re: Fallout 3: 3D Printed Power Armor Helmets
Looks good may i ask what kind of printer you are using ?
Looks good may i ask what kind of printer you are using ?
GhostMinion
Sr Member
Re: Fallout 3: 3D Printed Power Armor Helmets
Thanks guys!
For the helmet shells, I'm printing on my Lulzbot Taz 3. It has about a 12"x12" build platform, which allows me to print very big sections of the helmet at a time. The recent print shown took a whopping 84 hours to print, and during the entire print stayed completely adhered to the print bed.
The other parts that were already printed and molded (that are not in the recent print picture) were printed on a Replicator 2. Those parts have been mastered and ready for some time, so they'll be waiting for when the helmet shell casts are being pulled.
From this point on, however, all the little parts for all the rest of the helmets will be printed on my newest printer, a Form 2 SLA printer. This will ensure that the sharpest details are captured, which will be very handy when we get around to the T-60 helmet.
Thanks guys!
For the helmet shells, I'm printing on my Lulzbot Taz 3. It has about a 12"x12" build platform, which allows me to print very big sections of the helmet at a time. The recent print shown took a whopping 84 hours to print, and during the entire print stayed completely adhered to the print bed.
The other parts that were already printed and molded (that are not in the recent print picture) were printed on a Replicator 2. Those parts have been mastered and ready for some time, so they'll be waiting for when the helmet shell casts are being pulled.
From this point on, however, all the little parts for all the rest of the helmets will be printed on my newest printer, a Form 2 SLA printer. This will ensure that the sharpest details are captured, which will be very handy when we get around to the T-60 helmet.
Dspongberg
New Member
Re: Fallout 3: 3D Printed Power Armor Helmets
After looking at the build history I can help but see the resemblance between these two things...
I Really empathize with you about the temporary setback, It took two attempts to weld by NCR ranger mask together, the first attempt the welder basicly melted the sheet steel I was using so I had to completely re cut and bend all the bits.Huge props to you for coming back to it.
After looking at the build history I can help but see the resemblance between these two things...
I Really empathize with you about the temporary setback, It took two attempts to weld by NCR ranger mask together, the first attempt the welder basicly melted the sheet steel I was using so I had to completely re cut and bend all the bits.Huge props to you for coming back to it.
GhostMinion
Sr Member
Re: Fallout 3: 3D Printed Power Armor Helmets
Alrighty, time to get this project back to moving forward! Yesterday I finished re printing the FO3 T-51b helmet shell. Today I began welding the sections together. I printed the helmet shell in just three rather large pieces, as opposed to the five pieces I had cut the original helmet in. I also made a couple modifications to the model itself, widening both the hole you stick your head through as well as widening the hose outlets. Now my head actually fits in!!!
More to come on this bad boy very soon. Stay tuned.
Aside from that, I just the other day finished modeling the new FO4 T-51 helmet. This beauty is all ready for printing! This helmet will be set up just like the other T-51b helmet, as the headlamp will be able to be made functional and the optics bracket will be able to rotate up and down.
I plan to begin printing this immediately, and will be attempting to print the main helmet shell in just two halves. More to come soon on this as well.
Alrighty, time to get this project back to moving forward! Yesterday I finished re printing the FO3 T-51b helmet shell. Today I began welding the sections together. I printed the helmet shell in just three rather large pieces, as opposed to the five pieces I had cut the original helmet in. I also made a couple modifications to the model itself, widening both the hole you stick your head through as well as widening the hose outlets. Now my head actually fits in!!!
More to come on this bad boy very soon. Stay tuned.
Aside from that, I just the other day finished modeling the new FO4 T-51 helmet. This beauty is all ready for printing! This helmet will be set up just like the other T-51b helmet, as the headlamp will be able to be made functional and the optics bracket will be able to rotate up and down.
I plan to begin printing this immediately, and will be attempting to print the main helmet shell in just two halves. More to come soon on this as well.
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GhostMinion
Sr Member
Re: Fallout 3: 3D Printed Power Armor Helmets
New Fallout 4 version T-51 helmet printing has begun. The helmet is being printed in two massive halves, this one pictured took 127 hours to print!!! Next section is smaller, and I can cut the time down by tweeking my support material density. Overall, very pleased with the first print. Throughout all that print time, the helmet print stayed adhered perfectly to the print bed!
More coming on this, and the other T-51b helmet, soon.
EDIT: Sadly, the photos in this post were lost. Sorry!
New Fallout 4 version T-51 helmet printing has begun. The helmet is being printed in two massive halves, this one pictured took 127 hours to print!!! Next section is smaller, and I can cut the time down by tweeking my support material density. Overall, very pleased with the first print. Throughout all that print time, the helmet print stayed adhered perfectly to the print bed!
More coming on this, and the other T-51b helmet, soon.
EDIT: Sadly, the photos in this post were lost. Sorry!
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Re: Fallout 3: 3D Printed Power Armor Helmets
That is awesome! I hope by the time I can get one the print time speeds up! :lol
That is awesome! I hope by the time I can get one the print time speeds up! :lol
GhostMinion
Sr Member
Re: Fallout 3: 3D Printed Power Armor Helmets
Well, part of the reason it took so long was my fault. I've been experimenting with a feature my software has that allows you to change the density of your support material throughout the print. The trouble was, the feature measures the density differently than the way I usually do it, and so this was the first try and I just made it a little too dense. Having said that, the print sure as hell didn't suffer from having such ample support. The overhangs were clean as could be on the underside, so I suppose in reality it wasn't so bad.
The other reason it took so long is because the part is HUGE. It really doesn't look as big in the pics, but to hold it and think that this was just one print would blow you away. It's by far the biggest cut of a helmet I've ever printed, and if you've followed how I have printed the other helmets so far, you'll know I'm used to printing big. But this one definitely tops any of my personal records. What blows me away is that the print stayed perfectly adhered to the bed the whole time. Let it be known that a Lulzbot Taz 3 is a stone cold beast machine.
Well, part of the reason it took so long was my fault. I've been experimenting with a feature my software has that allows you to change the density of your support material throughout the print. The trouble was, the feature measures the density differently than the way I usually do it, and so this was the first try and I just made it a little too dense. Having said that, the print sure as hell didn't suffer from having such ample support. The overhangs were clean as could be on the underside, so I suppose in reality it wasn't so bad.
The other reason it took so long is because the part is HUGE. It really doesn't look as big in the pics, but to hold it and think that this was just one print would blow you away. It's by far the biggest cut of a helmet I've ever printed, and if you've followed how I have printed the other helmets so far, you'll know I'm used to printing big. But this one definitely tops any of my personal records. What blows me away is that the print stayed perfectly adhered to the bed the whole time. Let it be known that a Lulzbot Taz 3 is a stone cold beast machine.
GhostMinion
Sr Member
Re: Fallout 3: 3D Printed Power Armor Helmets
Yeah, it was brutal. It's bad enough waiting 80 hours for a print. Waiting 127 hours was just insane.
But the pay off will be when putting the two halves together. The less seams, the better. Sometimes the seams can be a pain in the butt..........
Yeah, it was brutal. It's bad enough waiting 80 hours for a print. Waiting 127 hours was just insane.
But the pay off will be when putting the two halves together. The less seams, the better. Sometimes the seams can be a pain in the butt..........
