The biggest reason why I wanted a big 3D printer is to print a helmet. The biggest reason why haven't printed one earlier is that it is a big project. I have dabbled with helmet designs for years but the designs I try seem to get uglier as they get closer to completion. This year I decided to try a new approach and make a modular platform that could be enhanced with add-on parts and accessories, so the look could be changed just by designing a new visor or other cowling. It was a major hurdle to design and print the basic helmet. As usual it is designed so the parts will print without support, but between that requirement and all the functional and aesthetic requirements it took days of reworking the design. It took 36 nail-biting hours to print, but printed perfectly, without even needing any cleanup, which was fortunate because I did not have enough filament to try a second time.
Here is a picture of the helmet on the beast of a printer that made it:
You can see it is close to the maximum size this printer can handle. It was hard to measure my head properly, but the final size is pretty good - I can just fit in from the bottom and there is room for pads inside.
Here is a little video of the helmet spinning on a headform I printed a long time ago:
I had obtained the animated eye displays long before this design took shape, but my idea of how to implement them has evolved a lot since I first conceptualized the feature.
Here is a video showing a bit of how the helmet was designed:
https://www.youtube.com/watch?v=o2oeSYGu4Ag
Here is a video of me wearing the helmet and being photo-bombed by a cat:
I took more video later with better choreography, but acting is not my strong suit (obviously) and I prefer this version with the cat antics.
I am still deciding what features to paint on the helmet and what the add-ons will look like, but that will likely wait until next year.
It has been a long journey learning about helmet design and I am so happy it has finally arrived at the wearable stage.
rsjawale24 made a comment below about storm trooper helmets that reminded me I have one (acquired shortly after the first Star Wars movie) that was a catalyst in getting me interested in designing a helmet, so I added this video:
https://www.youtube.com/watch?v=BV-QS4lNBIY
If you have suggestions for add-ons or paint schemes, please comment below.
Also still trying to come up with a suitable superhero name for what this helmet will become....
Relevant links:
Nightmare on e14 Street - Halloween 2021 Wearable Project Competition
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