Iron Man 3 Mark VIII (WIP) Updated 4/5

[EAGON]

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Canadianghandi and I are working on machining out the Iron Man Mark 8 helmet, we will soon post progression pictures. We received the file from skylu3Design | the RPF

This should be an interesting and challenging project.

 

[EAGON]

Re: Iron Man 3 Mark VIII

Day 1

I started breaking up some of the files into machinable parts. Canadianghandi started working writing toolpaths for the faceplate.

 

[ironmaided]

Re: Iron Man 3 Mark VIII

looks great

 

[bfb2bfb2]

Re: Iron Man 3 Mark VIII

Eagon, did u buy the helmet model from skylu3Design? If u did, may I know how much u payed for it?

 

[Canadianghandi]

Re: Iron Man 3 Mark VIII

I'm the one who purchased the file. I'm funding the project, we're using my machine and so on and so forth. Eagon is helping, he graduated with me from the same program and is a good friend.

As for how much I paid for it, I don't feel it's my place to disclose that. You can ask Skylu if you so desire.

 

[JR Tyner]

Re: Iron Man 3 Mark VIII

I will defiantly be following this project! It's always great when friends can work together like this. You get much better results than when one person does a project.

 

[xl97]

Re: Iron Man 3 Mark VIII

machined out of what? using what?


(also love it when I find other fellow cheesehead prop makers!) (I live in WI as well)

 

[Canadianghandi]

Re: Iron Man 3 Mark VIII

We are using my old 1987 Acroloc M12 3-axis CNC vertical machining center. It's nothing fancy but it will get the job done. We are using a combination of Surfcam and Bobcam to write the programs.

The helmet will be milled out of renshape, a urethane/tooling/model board, whatever you know it by. Afterwards we hope to make a mold using Smooth-on's rebound 25 series silicone. Still looking into what resin to cast it in.

I was hoping to have some parts machined by tomorrow night but I don't know if that will happen, just got some other jobs into the shop. We're still going to aim for Tuesday or Wednesday night to post some parts actually being cut.

(also, Go Pack Go )

 

[xl97]

Re: Iron Man 3 Mark VIII

awesome! (watching thread!)

(jealous of your machine access!)



(down in Milwaukee)

 

[Canadianghandi]

Re: Iron Man 3 Mark VIII

I would not be that jealous of my machine access. I bought it, had to pay for it to be moved into a shop, buy my own tooling, bought software, bought a computer for the shop..... Again, wouldn't be too jealous :lol

awesome! (watching thread!)

(jealous of your machine access!)



(down in Milwaukee)

 

[xl97]

Re: Iron Man 3 Mark VIII

well Im still jealous of the machine(s) you have... (maybe not the bills so much!) LOL

sure beats my 8x14 lathe and SX2 mill!

 

[EAGON]

Re: Iron Man 3 Mark VIII (WIP)

Day 2 of Work

We created the tool paths for the ear pieces on the side as the first part to machine because of level of difficulties. We then faced two pieces that were mirrored for each side and milled out the back side of each because it has a little pocket lip undercut on it from the back. Next we created a jig with precision ground pins to locate the part. The front side is currently cutting over night. Hopefully we can machine out the face plate soon.

 

[SpideyMan]

Re: Iron Man 3 Mark VIII (WIP)

Very nice looking forward to seeing the end product!

 

[Duncanator]

Re: Iron Man 3 Mark VIII (WIP)

You were talking about what resin to use. If you want to stay with
Smooth-On's product line, I'd recommend their 300 casting urethane.
It pours very nicely, is tintable, fast curing with little shrinkage.
If you need a slower cure time, they have other formulas.
Also, if you want to cast in color, their Color Match 325 can be tinted with
vibrant colors!

 

[Dark Zero]

Re: Iron Man 3 Mark VIII (WIP) Updated 2/26

I love seeing these threads with 3D/machining/printing pop up. Looking forward to see the result. Post lots of pictures of the progress

 

[EAGON]

Re: Iron Man 3 Mark VIII (WIP) Updated 2/26

Day 3

The side "ear" pieces turned out great they just need to be cleaned up a bit on the back side so they sit flat. We are currently setting up the face plate to be machined.

 

[skylu3Design]

Re: Iron Man 3 Mark VIII (WIP) Updated 2/27

Great to see is smooth with the progress, keep up!

 

[Canadianghandi]

Re: Iron Man 3 Mark VIII (WIP) Updated 2/27

Sorry for the lack of updates guys. A little busy at the start of the week. Mid week Eagon and I got together and started toolpathing what we feel is the hardest part, the face plate. We spent a few hours programming it, trying to get as much detail from the file as we can. Realistically the quality of the file is good enough that it should be 5-axis machined, which we lack, so we have what we have.

We used the same method on this part as we did the ears. Machined the first side (this side is VERY rough as it will not be seen), drilled holes for locating pins, drilled a jig, located the part with precision ground pins, and then finished the part. None of the pictures in this update will be the finished faceplate as it is still in the machine cutting.

Hope you enjoy and hopefully we will have a nice looking part in the morning.
-Canadianghandi

 

[CouchPotatoTalk]

Iron Man 3 Mark VIII (WIP) Updated 3/2

Really fine work so far! You're an excellent machinist. Will be bookmarking this forum to check on the progress

 

[Canadianghandi]

Re: Iron Man 3 Mark VIII (WIP) Updated 3/2

Real quick update.

Being that I'm 20 and dumb (life lesson story here), I cut corners and rushed this part. I broke a $40 cutter on the finishing pass..... Hopefully a new cutter should be here tuesday and we can have the faceplate finished Tuesday night