Making Molded Helmet Designs

Sunday, April 3, 2016 | By | Add a Comment

 

Making Molded Helmet Designs

Another recommended accessory for the cosplayer or semi-cosplayer at heart, is, of course, the helmet or head wear.  This often requires making molded helmet designs of your own creation in order to fit your unique alter ego.  Maybe Bruce Wayne wouldn’t care if he were to reveal his identity as Batman as long as his job get’s done, but for the sake of his protection, along with some cool gadgets in his helmet, it is safer for him to don the bat helm.

So, how does the helmet wearing cosplayer or semi-cosplayer go about creating their own headpiece.  Well, there are several ways of doing this, such as creating a CNC manufactured or 3D printed helmet of course.  I am not going to go into great detail about the processes, but I will talk about a process which I am familiar with which involves creating a clay molding for preparation of creating a casted helmet, much like the helmet in the video above.  This way involves hardening clay around a replica of your own head which can be a lifecasting of your head or something that could be used in place which is the same size and formation of your head.

When purchasing a clay for the mold, it is wise to go with NSP clay which is sulfur free clay, since sulfur will react with the curing chemicals in the rubber that is used for the mold, causing the clay to warp and the silicone not to cure properly.  Other clays that may be considered are oil based clays as well.  Always make sure that your floor is protected with some type of floor cover to prevent stains or ruining any carpeted area.

Once you have the clay, then you can start builiding it up in block like formations on the head replica.

Once you have built the clay up to represent the basic blocking of the subject, you can start sculpting it down to get more accurate shapes, contours, and details using finer and more precise tools.

Symmetry on both sides of the helmet is very important for a good looking helmet, just like a good looking head in real life, and I’m sure all the ladies would agree with me there, right?  You can use mineral spirits and a paint brush to smooth out areas and make sculpting easier and cut down on sanding time at the end of the project.

Once you’re satisfied, what you want to do is prep the sculpture for the molding process.  It is good to go over the entire sculpt with a few layers of primer to seal up the clay really good.  It will also take out any small scratches that the brush may have left.  So, now you should have a wonderfully symmetrical molding prepared for the casting process.

I hope you enjoyed learning more about creating a sculpted helmet design, and for more information on casting and casted designs, please take a look at the video above and stay tuned to the same bat website for more blogging on helmet creation in the future!

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Category: 3D Printing, Art, CAD, CAM, CNC, Cosplay, Design, Drafting, Fashion, Featured, Gaming, Manufacturing, Role-Playing, RPG, Smart Clothing, Solidworks, Video Gaming

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