3D printed Avengers Ultron helmet

http://www.3ders.org/articles/20150502-prop-artist-uses-3d-printer-to-create-a-full-size-wearable-avengers-ultron-helmet.html

Prop artist uses 3D printer to create a full size wearable Avengers Ultron helmet

With the release of the latest Avengers Movie – Avengers: Age of Ultron – in theaters today, there’s likely to be quite a few participants of the cosplay community who will either be coming out with their latest Avengers-inspired costumes or, after seeing the movie, will be inspired to go home and start on their next cosplay costume project.

Among those who have already gotten a head start on developing their Avengers-themed cosplay costumes is Michael Ruddy, a popular cosplay artist who uses additive manufacturing technologies to bring his costume ideas to life.  Recently, Ruddy used his new gMax 1.5 XT 3D to print a full size, wearable Ultron helmet for a special client.

The gMax 1.5 XT, which is manufactured by gCreate, features 4,608 cubic inches of build volume – which is the best price-to-volume ratio for a 3D printer currently available on the market.  Although he could have printed the entire helmet in a single pass thanks to the gMax 1.5 XT 16” x 16” X 18” print volume capabilities, Michael elected to divide the helmet into four separate prints – jaw, main face, top, and ears. The jaw was printed at 0.15mm layer height and took roughly 13 hours. The main face portion was printed at 0.2mm layer height and took about 30 hours, with the ears at 0.15mm layer height for an additional 10 hours. Finally, the top half was printed at 0.3mm layer height and also took around 30 hours due to placing supports in the middle.

After Ruddy’s client – Sean Shaw of Shawshank Cosplay Props – received his 3D printed Ultron helmet, he immediately assembled the jaw, face, top and ear parts into a final assembly with glue.

Once it was determined that everything fit as intended and was the proper scale, Shaw used car bondon to fill the part lines of the assembly before sanding down the entire assembled mask.  Once he had reached a more finished stage, he followed the bondo with XTC-3D by Smooth On to further fill and smooth any remaining imperfections on the mask’s surfaces.

Once all of the mask’s surfaces were finished, the mask was molded using Smooth On silicone (Rebound 25 and Smooth Cast 300) to create a high-resolution mold from the original 3D print.

Finally, after casting the mask, the result was a wearable Ultron helmet that’s perfect for any Avengers fan – thanks in no small part, of course, to the ease of desktop and affordable 3D printing.

References:

3ders.org

by Simon | May 2, 2015

http://www.3ders.org/articles/20150502-prop-artist-uses-3d-printer-to-create-a-full-size-wearable-avengers-ultron-helmet.html

3D printed Assassin’s Creed Blade

If you’re an Assassin’s Creed fan the signature retractable blade must have fascinated you at some point.

Farell Rozan loved it so much he designed and printed this working prop based on ‘Black Flag’. Follow the link below to check out his design in more detail!

http://3dprint.com/18863/assassins-creed-blade-3d-print/

We have seen our fair share of 3D printed props based on those found within video games. In fact, there are a whole slew of cosplayers who rely on many of these props to express themselves in a type of performance art. 3D printing has taken prop making, added precision and complexity, and has allowed for much more realistic pieces to be made.

One such piece was recently created by a man named Farell Rozan, based off of one of his favorite games, Assassin’s Creed IV: Black Flag. The game, set in the early 18th century during the Golden Age of Piracy, and developed by Ubisoft Montreal, pits players against one another or the computer, in a fun, intriguing, stealth action-adventure.

Rozan had recently purchased a Flashforge Creator pro 3D printer and wanted to create something fun, yet a bit challenging for his first project. What better an item to choose than the Assassin’s Creed blade.

“The Assassins Creed Blade is actually my first major 3D print project. I’ve been wanting to explore printing a model that has a mechanism, with moving parts, plus utilizing dual printing,” explained Rozan to 3DPrint.com. “Since it’s my first [project], I wanted to make something simple that has a trigger and performs an action. Making a gun requires a lot of mechanical parts so that’s not an option for a beginner. I’ve been playing the Assassin’s Creed: Black Flag, and I thought the hidden blade was perfect for the job! I’ve always admired the mechanism of the blade and how stealthy it is.”

Once this decision was made, Rozan scoured the internet for the perfect model. After searching Thingiverse and Youtube for quite a while, all the models he found were quite large, needing a thick handle to enclose the mechanisms required for the retraction of the blade. Unfulfilled, Rozan decided that the only way he was going to 3D print a blade he’d be satisfied with, was to design it himself.

“Using Google Sketchup, I designed the model that utilizes a rubber band and a trigger-release in the mechanism,” explained Rozan. “With parts that hold the blade sturdily during extraction, and a few braces to hold the body frame together.”

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Being a newcomer to 3D printing, Rozan had difficulty calibrating his printer and had to reexamine several areas of his design. One of the main design flaws he had experienced, was that of not allowing for the proper amount of gap tolerance. Additionally, it was difficult for Rozan to figure out the correct amount of infill to use so that the blade, which was printed with the more tolerant ABS thermoplastic, would not bend or snap very easily. After his 4th design, and learning a great deal about modelling and printing in three dimensions, he felt he had perfected his creation. Judging by the images and videos Rozan has provided us, I think he may be right. Rozan discussed with us what he has learned from this project:

“It’s better to simplify the parts to allow some tolerance in minor print defects. Also, it’s always an option to fix some model parts during the post process rather than fixing the 3D model for accuracy. Printer calibration is key. There’s a lot of times where I thought the defects came from errors from my 3D model, but it turned out it was due to the printer calibration. The orientation of your model while printing is also key for making high strength parts.”

In total, the final blade took about 12 hours to print out on the Flashforge Creator pro. Once printed, it took Rozan an additional 4 hours for post-processing. The entire blade is made up of 42 parts, which include rubber bands and wrist straps in addition to the 3D printed pieces. Let’s hear your thoughts on Rozan’s creation, in the 3D Printed Assassin’s Creed Blade forum thread on 3DPB.com.

3DPRINT.COM
by  | OCTOBER 12, 2014