My Styrene Pepakura Ironman helmet

Thank you for this. My mk42 helmet warped on me. I feel like I might try the faceplate out with styrene and see where I end up.

Great tutorial. It is very helpful! Ill harass you next week with more questions haha
 
EnderX said:
Thank you for this. My mk42 helmet warped on me. I feel like I might try the faceplate out with styrene and see where I end up.

Great tutorial. It is very helpful! Ill harass you next week with more questions haha
Click to expand...


You're welcome and good luck. I'm happy to answer any questions you may have. :thumbsup
 
What a gorgeous build! Amazing craftsmanship!

Your molds are interesting.

Is there only silicon touching one side of the part face? Is the other side just your gypsum cement/plaster?

I've never seen a mold like that. Is there a chance that the resin might stick to the plaster or do you just coat that part in mold release thoroughly?

my-styrene-pepakura-ironman-helmet-.jpg



Looking at it again right now is this just a open face mold and the white stuff under the grey part just a styrene base put there for molding against. Is the silicon brushed on?

Nick
 
Simply PHENOMENAL!!!!

Excellent Work dude... the level of craftsmanship is over the top :):thumbsup

That is real talent and skill there (not talented 3D printer... LOL:lol) ...
You must be real proud of your work :) (well you should be ;):thumbsup)

Keep building man... cheers!
 
nick daring said:
What a gorgeous build! Amazing craftsmanship!

Your molds are interesting.

Is there only silicon touching one side of the part face? Is the other side just your gypsum cement/plaster?

I've never seen a mold like that. Is there a chance that the resin might stick to the plaster or do you just coat that part in mold release thoroughly?

my-styrene-pepakura-ironman-helmet-.jpg



Looking at it again right now is this just a open face mold and the white stuff under the grey part just a styrene base put there for molding against. Is the silicon brushed on?

Nick
Click to expand...

Hi Nick

I took a couple of pics of the mold of the main helmet part to describe how I did the molds :

Pic 1 - The main part of the helmet blocked off with styrene and mounted on a piece of MDF with alignment keys drilled into the styrene base.

Pic 2 - The main part of the helmet covered in a layer of clay. The clay will be removed once you've done the mother mold and will form the cavity you pour your silicone into.

Pic 3 - The clay covered part covered in plaster to form the outer casing or mother mold. Please note that this pic isn't the pic of the clay covered master I ended up using, but should give you an idea as the process was exactly the same. Initially I intended on making a 2 part mother mold but decided against it and went with an easier 1 part mold instead.

Pic 4 - This is the result once the clay is removed and the silicone is poured into the mother mold. I brushed on 2 thin layers of silicone just to be sure I didn't trap any air and filled in the areas I thought may form air pockets before pouring the silicone into the hole on the top of the mother mold. The shape and thickness of the silicone mold depends on the shape and thickness of the clay described in pic 2.

As to your questions about resin sticking to the plaster. I thought I would just use some shrink-wrap wedged in between the silicone mold and the mother mold an let it drape down the sides of the mother mold. This should form enough of a barrier to protect the mother mold from resin sticking to it. A thick layer of release agent probably couldn't hurt either.

I hope this answers some of your questions.
 
I just bought some styrene sheets too and they're pretty cheap. I bought some 0.03 (thickness of a credit card) and some 0.06 and redo my whole Iron Man suit from scratch.
 
Tigerblood said:
I just bought some styrene sheets too and they're pretty cheap. I bought some 0.03 (thickness of a credit card) and some 0.06 and redo my whole Iron Man suit from scratch.
Click to expand...

Good luck with the build. If you need any advice please let me know. :thumbsup

Remember to wear a dust filter when sanding the styrene.
 
I'm super interested in the mold process. Anyway you could make a little vid?

Its looks GREAT so far! I am really impressed! You and another guy from the Phillipines are the two best I've seen so far.

Tank
 
ShermanTank said:
I'm super interested in the mold process. Anyway you could make a little vid?

Its looks GREAT so far! I am really impressed! You and another guy from the Phillipines are the two best I've seen so far.

Tank
Click to expand...

Thanks. Unfortunately I'll have to try and make a vid or at least take pictures of the mold making process on the next one which will probably be the Vader.

If you have any questions on how I did the molds, please let me know and I'll be happy to try and explain the best I can.
 
hi i would like to know which file you use '?
are u able to share it as i cant find 3 parts iron man helmet file
 
I've been snooping around the forum for quite some time now, trying to learn about prop making pepakura etc, but honestly this is the most mind blowing iron man helmet, in term of construction method and detail, in comparison to paper pepakura, that I have found. Congrats for a job well done.

ps. I can feel your frustration for not being able to find what for our US friends is so easy. Imagine that I can not even find styrene sheets... At least not easily and on retail... (I am from Greece and such kind of crafting is not really known here...)

Thumbs up!!!
 
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