Star Wars Rogue One Rebel Helmet - First Run of 50

The printed helmet armor is on its way over to Florida USA to be cast by Mr Mold Maker a great member of the RPF. almost all of the interested parties are from the US so having it cast and posted from there made sense.

 

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Star Wars Rogue One Rebel Helmet - First Run of 50

Rogue One, The best Star Wars yet!
 
I have teamed up with Jack to cast a run of 50 resin helmet armor pieces and Sarah to make the fabric covers.

 Here are the Final renders, I have 1/2 of the armor printed. Come next Wednesday the 3d printed parts will be on their way to the USA.

If you are interested in getting one head to the RPF to find out more.
http://www.therpf.com/showthread.php?t=269695

Merry Christmas!

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Star Wars Rogue One Rebel Helmet - finshed

The Premier is tonight!
I have my helmet.

 Saw Gerrera: What will you do when they catch you? What will you do if they break you? If you continue to fight, what will you become?

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Star Wars Rogue One Rebel Helmet - 2 days togo!

The good thing about the future resin cast ones is that they will be one piece so they will be solid with a lot less flex. I have already made adjustments to the files to accommodate the extra close spots and taken a few spot in a tad. This is because of the extra fabric thickness in places.

3d printed prototype
Unfortunatly putting the helmet on and off and squashing it on to the fabric has weakend the joint so you can just make them out lucky they will be cast in resin in the future.

Peel of the masking tonight and clear coat ready for the premier.

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Star Wars Rogue One Rebel Helmet - 4 days to go!

4 days to go for the premier and I think I will have a pretty good Helmet to wear to the premier.
Still needs the back grill section so will be cutting it close. Whats next is to give a few washes of blue and green and some black to dull it down and give it a little extra interest.

Lighting is a little different in the trailer shot below but I think it will be pretty close after some washes.

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Star Wars Rogue One Rebel - Left chest Greeblie

I used a Rogue One trailer screen grab from Cassian's chest greeblie and a few other references. It looks close enough for the Premier. I might make it more accurate once I get more info.

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Star Wars Rogue One Rebel Helmet - Fabric

It was a big challenge figuring out the top section but  I was lucky enough for my cousin to be in town for December for a visit and Christmas. She is a clothing designer and was able make a patten from the reference material.

we calculated from the poster image that there are 10.5 ribbed sections and after a few tests we have a prototype.

The bottom strip is perfect.

 The Helmet with the top section pinned. Sorry its blurry only one I took.

 Started painting the Armour too. 

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Star Wars Rogue One Rebel Helmet - 3d Printed Mk2

Finished printing and prepping the next version of the helmet, looks much closer still a few things I might change but its defiantly close enough for the premier next week.

The helmet looks like a black or super dark grey. Looking at the Lego figure I picked up, it has the smallest metallic specs. fairly sure its metallic going by that. I think I will go for a super dark grey metallic.

Next is to finish the fabric cover for the helmet, then paint and weather the printed part.

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Star Wars Rogue One Rebel Helmet - 3d Printed Prototype

After hours of deliberation over the reference material and replicating it in fusion 360 I have something to show that is tangible. I'm very pleased that the ReMake software was successful in converting the M1 helmet to to a 3d model and that I was able to scale it correctly. Now that the armor piece has been printed it actually fits over the helmet snug with a little room around the top for the padding that will be sewn into the baffles giving the helmet that rebel feel.  The 1st prototype is pretty close and having it in hand enables me to make a few changes.

The changes are;
Slightly lower the front brim of the armor.
Bring the rear top angle section further around.
The back grill panel needs to curve around the helmet more to match the top angle which will give more room for the grill section, and most of all be more accurate. 


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Star Wars Rogue One Rebel Helmet - Helmet Armor Mk3 Renders 95% done.

I'm very close to finishing the design work, the front is complete. The back needs some tweaking to match the reference material. Then separate it into printable sections, I want to make the vent section completely separate so on the off chance its not 99% I can swap it out.

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Star Wars Rogue One Rebel Helmet - Helmet Armor Mk3 Back Details

After the new pictures that have surfaced, the back profile of other rebel helmets, and the Lego figure of the trooper I was able to continue the back details.Getting close now.

I need to fill in the back of the slots but other than that I'm pretty pleased.

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