Slow on update for a while, but work has not been idle.
Some weeks ago I took the 3 different scans I've been able to make. And lined them all up as best I could with each other, as well as my original model I made prior to this. Then used the areas from each that looked accurate and reliable. Deleted everything from my on original model that overlapped and the merged it all together.
I'm very satisfied with the result, the new model is much more accurate than my first model. I'm under no illusion that is perfect, but I think its as accurate as I can make it.
Next up I modeled the mouth area, where there are lots of tiny hole. And this part is not mirrored, so I had to model each of the separately. This make the scene much more complicated, since I wish to keep the rest of the model mirrored for as long as possible. So this area is sort of cut out from the rest.
I also modeled all of the inside. I had previously made a bust of myself. On top of which I then made a paper mache mask that covered my entire head. This one i can easily take on and off, so it a great references for the inside of the helmet. So I scanned that, and make a clean model out of it, I can be pretty certain that the helmet will fit me once I print it.
I also added some rectangular cavities on the inside where I intend to put some foam, so that it fits snug on my head and hopefully will not slide around. I made the inside slightly larger than it needs to be, so I get a little bit of a gap. I'm hoping to get at least a little bit of airflow.
So after this the base model is complete. Next up was all the details. So here I needed to learn some new things. I may be a veteran 3D artist, but I'm new to blender, so time to learn UV mapping again. Pretty straight forward. Once UV mapped I textured it cutting out reference from photos, mostly for the areas in the front where there are patterns.
Traced those patterns. Not that easy since there is a lot of weathering in the helmet, the details are intentionally worn away. So I have to interpret the intent behind the detail, and then add my own damage on top, so the damage is consistent across the helmet.
And here is where things slowed down. What to do with the worn look?
Originally I was actually intending to do the entire armor in a more pristine state. So that all the details would be there, even stuff that is completely worn away on the movie armor. But this started to feel wrong, a completely smooth perfect armor will look odd. Sure Sauron was a master smith, and like beauty, but I want the armor to feel mostly like the one in the movie. So damage it is.
Thing is, whatever type of damage I add to the helmet, is probably going to be what I will also add to the rest of the armor. So its a big decision. That, and the tools of how to do it slowed down things a lot too. Should I do it in Photoshop? no its too limiting in creating the texture? Substance designer? I would prefer to keep down the amount of tools i used to keep the pipeline simpler. So I made a shader in blender, and rendered to texture.
The amount of damage is also a question, the replica helmet is very uneven, with multiple layer sand scale of damage. If I were to do that, then the model would be 20 or 40 million triangles, and it cant really be optimized without removing lots of detail. I would also probably be forced to work in Z-brush to even handle it. And trying to import a 17 million triangle model into the slicer, took 20 minutes, and it often crashed when trying to cut it up. So I'm going to have to limit the amount of detail in the printed model a bit. If I want more detail I will have to add after i print it, which I am considering.
So to test if the patterns will turn out well, i made some test prints, doing different amount of depth. 0.5, 0.7, 1.0, 1.3 mm depth. In the end I went with 1.0 depth.
Becasue the model is so heavy, I use a decimate modifier, which persevere most of the details I want, while going from 17 million triangles to about 1,5 million, much more manageable. I also decided to cut up the model in blender instead of the slicer. The displacement and optimization and cut up was not without flaws though, and i've probably spent a good 20 hours cleaning it up and making it ready for print. So if for whatever reason something is really off, its going to be big setback. The prusa Mk3 has a printbed of 21x25cm. Which is a very tight fit for me. I could of course cut it up more, but i really dont want to.
The helmet will take 8 days to print, baring any failed prints. I guess time will tell.