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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Star Wars Rogue One Rebel Helmet - Helmet Armor Mk2 First Piece Printed

Printed the first piece, I'm really impressed with how well ReMake captured the helmet. The piece will need a small amount of modification.  Changing the location of the bottom crescent shape holes down a bit and adjusting the angle of the grooves going up the helmet so they match the fabric closer. . . .

I have just got a brand new Image and it clearly shows the helmet is a complete ring so this is not correct any more. I think thats very in line with the rebel helmets on Endor.  A few changes tonight and I think we will be ready to start the printing the whole thing. Im Very pleased with the flashlight, thats Bang on.

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Star Wars Rogue One Rebel Helmet - Helmet Armor Mk2 ready to print

I need to modify my roller for the printer I brought a 3kg spool of filament and it doesn't fit. So will adjust that tonight after work and get printing (and continue the back). I left the back for reference, You might also notice I changed the angle a tiny amount so that the grooves going up the helmet are a nice curve rather than kicking out at the bottom.

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Star Wars Rogue One Rebel Helmet - Helmet Armor Mk2

Progress, I have the main shape done, possibly some tweaking later on, I will continue tonight. Still a bit of editing to get the holes and back piece finished. I feel much better about this version. I plan on giving the armor a 2mm buffer between helmet and armor.

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Star Wars Rogue One Rebel Helmet - Helmet Armor Mk2

The new Rogue One trailer has added a few extra seconds of footage that has enabled me to get the details I needed to continue the work on the helmet armor.

If your interested in the armor there is a run coming together on the RPF, as you can see its still in the process of design but hope to have a printed test armor by the end of the week all things going to plan, then I send to files to the USA for another RPF member to roto cast.

I was not completely happy with the first version of the armor. My problem was I wanted to ensure that when I printed out the helmet armor it would be a tidy fit around the M1 helmet. So after a fair bit of thought and a discussion with a friend I started to look at photo aps that convert images to 3d objects. I used autocad ReMake.

After Processing and editing.

 Once that was done I exported it to Fusion 360 and started work.

Once I was happy that I had the initial shape I imported a few background canvas's and adjusted them to fit. 

That's what I have so far, The work continues.

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Rogue One - Shoretrooper Heavy Blaster E 22

The New Shore Trooper has an upgraded E 11. Double barrel and stock.

I got the files from the facebook page R1 troopers (Sean Fields), Fantastic. No modification needed and no tinkering on my end. I have my own Helmet to work on, so while I'm working on that I have the printer working on this blaster.

Hot off the press an update for a few extra parts.

Main barrel, scope, back barrel connector and barrel tip.

Starting to resemble the actual pic now, just a little. Plumbing drain pipe works great for the internals of the main, I will have to check back at the local to see if I can get some 22mm pipe or dowel to run the length for straightening and strenght.