Mandalorian Mercs Costume Club

Mandalorian Armor => Armor Construction => Topic started by: Valkir on May 21, 2015, 09:03 PM

Title: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on May 21, 2015, 09:03 PM
I have started the CAD side of my Late Crusade armor, I wanted to make sure using a specific model from SWTOR was acceptable before I began work as this will be an intensive build in time and money.

http://mandalorianmercs.org/forum/index.php?topic=92867.msg1358382#msg1358382

I work in CAD making miniatures for table top gaming as my day job, so when I wanted to feed my Boba Fett-ish it seemed a natural choice.

I am tall, 6’5” so I am a bit large for a canon Boba, I have no interest in making a Vader or Wookie costume…. Poking around I found you guys and as I sometimes play SWTOR I had just the thing in mind 

I will use an FDM printer to bring the CAD files into the real world as wearable armor. Here is my ultimate goal. I wanted to keep it as true to the original model as I could so I made a set of cardboard calipers and started measuring my knoggin. 10” deep tip of the nose to back of the skull, 7.25” wide ear to ear and 9.5” tall chin to top of head.

I took a CAD human dummy and started my tweaking there, this provided me with a 3D representation of my head dimensions. As I use Rhino 3D for my CAD work, it provides accurate measurements down to the micron. I use Zbrush for most of my organic modeling but nothing does hard plate armor like Rhino.

(http://2.bp.blogspot.com/-rnZyPjRCxqc/VVr1Gt5Xs1I/AAAAAAAAEd8/jtGT3TRvwR8/s1600/Late-Crusades-Heavy.jpg)

This is where I begin my journey… Using screen grabs from the game I start roughing in the initial shape, knowing full well a bucket with tapered sided was not the final goal.

(http://2.bp.blogspot.com/-hoXDYT8Nm28/VV50k99zccI/AAAAAAAAEec/Zu3zJ_-bRkk/s1600/WIP.jpg)

You can see me working through the process, refining the shape. The shape is a little more complex than you would think, there is a change in form at the front of the helmet, it’s not just a cut the nose off kind of thing. After a couple hours of tweaking I have the basic form where I want it but I need to go back and rebuild the face area from scratch to refine the eye slot and the nose area and make the design fit as close as I can get it to the in game model.

While working through this process, I discovered the ears were not in the right place for a human… I had to move their position and refine the helmet details to match their revised placement.


Here you can see a 95% completed helmet.
I threw some quickie textures on it just to give it a spin. As Shea Viz has some great close up art I patterned my mic tips? off of hers. I tried to copy every detail present in the game model. The game model is fairly plain but that’s fine by me as it more closely matches Fett, where Shea Viz is much more busy and the shape of her helmet more curved and form fitting.

(http://4.bp.blogspot.com/-ABCJoAOBlZM/VV50kxafXZI/AAAAAAAAEeg/Z-UPPv7L6QQ/s1600/render1.jpg)

(http://3.bp.blogspot.com/-6pFXyfEcbTo/VV50k5Lt28I/AAAAAAAAEeY/behyub0IEIs/s1600/render2.jpg)

(http://2.bp.blogspot.com/-H2qv46MBcgE/VV50lcLvAvI/AAAAAAAAEeo/OqSYN_p1XCo/s1600/render3.jpg)

(http://3.bp.blogspot.com/-bIMHksKVQ6k/VV50lvyglTI/AAAAAAAAEew/RuwUpLmJWVo/s1600/render4.JPG)

I will keep this build log rolling until the entire armor is complete, I thank you for stopping in and viewing my WIP. Please feel free to make suggestions or ask questions.

All the best!
V
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based)
Post by: Boz Ving on May 21, 2015, 09:13 PM
Dude that's amazing!
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based)
Post by: Briks on May 21, 2015, 09:30 PM
I really like that helmet look  8) Can't wait to see more progress!  ;)
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based)
Post by: YourMaster on May 21, 2015, 09:35 PM
 I likes it a lot too but how u print somthing that big in sections?
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based)
Post by: Valkir on May 21, 2015, 09:40 PM
I likes it a lot too but how u print somthing that big in sections?

The printer I have coming will deal with 12" square, so the helmet will be one piece the chest will need to be broken up.

(The small detail parts on the helmet will need to be done on a different printer, as FDM does not give the surface quality for small details.)
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based)
Post by: Ralin Voth on May 22, 2015, 02:59 AM
You have entirely too much skill vod. I can't wait to see how this turns out.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based)
Post by: Mando707 on May 23, 2015, 03:40 AM
I don't even know whAt To say ... Aside from Rock and Roll... Doesn't look like anything I've ever seen in Star Wars land, but what do I know? Incredible job and can't wait to see this project I'm real life.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based)
Post by: Valkir on May 24, 2015, 11:28 PM
I don't even know whAt To say ... Aside from Rock and Roll... Doesn't look like anything I've ever seen in Star Wars land, but what do I know? Incredible job and can't wait to see this project I'm real life.

Heh, yeah it comes from the Star Wars The Old Republic MMO... I hear you though, A lot of designs coming from the comic books are new to me. This kind of thing like the comic books fall under the 'expanded universe'.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based)
Post by: Zeafus on May 24, 2015, 11:41 PM
I hope i run into you one day so i can check out that helmet in person. Its freaking sweet
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based)
Post by: Valkir on May 31, 2016, 04:26 AM
The long wait for the Kickstarter printer is over!

My Raise3D N2Plus arrived in good condition. After a few small test prints to get the feel for the software, printer and materials I finished up the helmet and jumped right in.


I settled on PETG as my build material, it has some flexibility and is very impact resistant. PETG can be a pain to print in and there are very few solvents that can be used to glue parts together, lucky for me, this is a monster sized printer.

I needed to do a bit more work on the CAD model and shell the model for the proper wall thickness, I tried to keep it at about 1/4 inch thickness for strength.
I removed the ears and mic. to print them separately, I made the ear sections hollow so that I could put some screening over some small detail holes to aid in hearing while the helmet is on. I may take apart some shooters ear muffs and put the electronics in to use as amplifiers.

(https://1.bp.blogspot.com/-oyw4FNSfI7Y/V01H4o0MhvI/AAAAAAAAEsw/H2u69A3Ol2IVm3nqcqe8JNzLwiLwKOLHQCLcB/s1600/shelled%2Bhelmet%2B2.jpg)


(https://1.bp.blogspot.com/-4yRbQSEUZYI/V01H4s49sPI/AAAAAAAAEs0/3uBe9YDxk7QijtuOP_FodTm-4nlj2VxUwCLcB/s1600/shelled%2Bhelmet.jpg)

Here is the first shot of the helmet being printed, we are about 24 hours in on a print that will take nearly 200 hours to complete. I could have easily done it in a quarter of the time but that would mean a less desirable finish and more time spent on cleanup... Plus this gives me a good chance to work out if there are issues with the printer as a torture test will show if there are mechanical issues I need to worry about.

(https://3.bp.blogspot.com/-7i6j30TGlOM/V01H4aI-0mI/AAAAAAAAEss/6bUp5aEpEpwm3DUftiJhpLkqi5gCRh-hgCLcB/s1600/Machine.jpg)

(https://2.bp.blogspot.com/-3g_BpNJSopI/V01H4VJoQPI/AAAAAAAAEso/7kkaGxnitXkPNc-AUkjdXhe49cemxIpWwCLcB/s1600/display.jpg)
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based)
Post by: Sulkon88 on May 31, 2016, 04:56 AM
Amazing! How much does a printer that can build that large of an object run for? If you dont mind me asking.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based)
Post by: Valkir on May 31, 2016, 05:05 AM
The kickstarter price was $2600 or so. They are now $3300.00 still expensive but compared to a makerbot Z18 at $6300.00 its one hell of a deal. Heated bed and enclosed with a 12x12x24 build area. So far it has been stupid simple to operate and is giving great results so I am pleased with the printer.

You can take a gander here:
http://www.raise3d.com/products/raise3d-n2-plus-pre-order-fdm-3d-printer (http://www.raise3d.com/products/raise3d-n2-plus-pre-order-fdm-3d-printer)

Title: Re: Valkir's WIP Late Crusade armor (SWTOR based)
Post by: Zeafus on May 31, 2016, 10:21 AM
The long wait for the Kickstarter printer is over!

My Raise3D N2Plus arrived in good condition. After a few small test prints to get the feel for the software, printer and materials I finished up the helmet and jumped right in.


I settled on PETG as my build material, it has some flexibility and is very impact resistant. PETG can be a pain to print in and there are very few solvents that can be used to glue parts together, lucky for me, this is a monster sized printer.

I needed to do a bit more work on the CAD model and shell the model for the proper wall thickness, I tried to keep it at about 1/4 inch thickness for strength.
I removed the ears and mic. to print them separately, I made the ear sections hollow so that I could put some screening over some small detail holes to aid in hearing while the helmet is on. I may take apart some shooters ear muffs and put the electronics in to use as amplifiers.

(https://1.bp.blogspot.com/-oyw4FNSfI7Y/V01H4o0MhvI/AAAAAAAAEsw/H2u69A3Ol2IVm3nqcqe8JNzLwiLwKOLHQCLcB/s1600/shelled%2Bhelmet%2B2.jpg)


(https://1.bp.blogspot.com/-4yRbQSEUZYI/V01H4s49sPI/AAAAAAAAEs0/3uBe9YDxk7QijtuOP_FodTm-4nlj2VxUwCLcB/s1600/shelled%2Bhelmet.jpg)

Here is the first shot of the helmet being printed, we are about 24 hours in on a print that will take nearly 200 hours to complete. I could have easily done it in a quarter of the time but that would mean a less desirable finish and more time spent on cleanup... Plus this gives me a good chance to work out if there are issues with the printer as a torture test will show if there are mechanical issues I need to worry about.

(https://3.bp.blogspot.com/-7i6j30TGlOM/V01H4aI-0mI/AAAAAAAAEss/6bUp5aEpEpwm3DUftiJhpLkqi5gCRh-hgCLcB/s1600/Machine.jpg)

(https://2.bp.blogspot.com/-3g_BpNJSopI/V01H4VJoQPI/AAAAAAAAEso/7kkaGxnitXkPNc-AUkjdXhe49cemxIpWwCLcB/s1600/display.jpg)

This bucket makes me giggle from how awesome it looks. Im so excited to see it finished.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jun 03, 2016, 02:47 PM
I restarted the print last night, it was not liking being printed with the helmet upside down. The supports on the inside were not sticking to the inside walls. I flipped it over as the supports should have no problem when attached to the build table.

I also changed the thickness of the walls down to about 3/16. the 1/4+ was overkill. I could have beaten the helmet with a 2X4 and I doubt you could break it and the added weight was not needed. Guess I just needed to sacrifice a spool of filament to the print gods...

Second print started last night, about 100 hours remaining.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Den Barren on Jun 03, 2016, 02:54 PM
Vod this is beyond awesome!
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: jedisalamander on Jun 03, 2016, 03:01 PM
would you release the file you used for this armor on thingiverse?
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: NeX on Jun 19, 2016, 07:05 AM
would you release the file you used for this armor on thingiverse?

^ this
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jun 19, 2016, 02:16 PM
I have been busy with a few other things so my posts are not as timely as I would like.

(https://4.bp.blogspot.com/-QXZVvPDD1Fw/V2bZhUokYQI/AAAAAAAAEtY/KafyFKCNLEUhFFwS9cqdz47lMO8rmT40wCLcB/s1600/almost-done.jpg)

Here you can see the helmet nearly complete, this was my third attempt at printing, I had turned it the other way but had a nozzle clog and some support issues. It wasted a lot of support material when it was sitting right side up so I decided to change the type of support to a more robust format, this would make cleaning more difficult but the supports would be more secure. So I flipped it over and started again.

I had some issue with Y axis wobble in the print, leaving a wobbly print the closer it got to the door (termination of the Y axis) Not a big deal as I can clean that up but certainly not ideal… I will be looking for the cause and fix shortly. Likely it is a loose screw or belt on that axis that I will need to look after.

Happy to see a completed print, I removed it from the bed and got to work removing the supports and putting down the first layer of primer to start the surface cleanup… Lots of work to be done. I ordered some files, which are on the way to assist in cleaning out some of the areas such as the ridges in the helmet.

(https://3.bp.blogspot.com/-YX8XuxGjoq0/V2bZhaa2z4I/AAAAAAAAEtc/j_3NsQHeUK0fcbidFL51hUPS3senQKdJACLcB/s1600/Helm1.jpg)


(https://3.bp.blogspot.com/-P10ZFBpd_wE/V2bZghYi2oI/AAAAAAAAEtU/cdzdho7FwegsFT2U7N1tMbcCdwDC6zhzwCLcB/s1600/Helm-2.jpg)


(https://1.bp.blogspot.com/-QRr1Qu-uZpY/V2bZgjK-3YI/AAAAAAAAEtQ/CvYaPEGyjSssLjRcIFeXKEbmyBVZmF92QCLcB/s1600/Helm-side.jpg)


While I wait on the files, I started printing the ear sections.

(https://1.bp.blogspot.com/-8v6SHYibtQs/V2bZgq7pMqI/AAAAAAAAEtM/ffbBz1ZfMcU2Vo1kstLgo89x9AYccYwEACLcB/s1600/Ears.jpg)


As to your question, will I post the file, Yes, I intend to but likely not on the normal public channels, I want them to be available to the Mando Mercs but I have not liked the trend of late of people grabbing them and selling them on Ebay. I need to give it some thought and find a good solution that makes it available to you but keeps it away from those that profiteer from others time and energy. Yeah I know, it will likely end up there anyways but I will do what I can.

Anyways, still working out the first print to see if I need to revise anything or if I can improve the design, like making the ear details twist on so you can have access to any electronics you want to place in them, lights, sound amp, etc.


Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Mojo Khuriso on Jun 19, 2016, 02:26 PM
That's some incredible work!! As an avid player of SWTOR...that bucket is spot on!!! Can't wait to see this completed!!!
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jun 19, 2016, 02:35 PM
Thanks Vod, I try  :P

Having the ortho views from the game was a huge help, then being able to go back on the game, spin my toon and then spin the CAD work to confirm was also a huge help on keeping it as close as possible.

Size wise, its about the same as the cheap Jengo helmet you can get at Amazon but due to its design, slightly more narrow and slightly longer front to back. My nose touches the front of the Jengo, but I have plenty of clearance with this bucket. Those with wide heads might have an issue with this bucket? If you measure ear tip to ear tip (side to side) by use of cardboard calipers and you come up with a measurement more than 6.75" (6.5" or less being optimal) it may not be so comfortable to get on and off... The open ear design allows for your ears to fill the large opening on the side once its on but if you knoggin is wide, it might be a squeeze until it sits where it is supposed to.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Jonathan Rudy on Jun 23, 2016, 10:59 AM
Good lord that is amazing.

If you decide to mold that and make production copies, let us ALL know. That bucket is amazing.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: aforklikeutensil on Jun 23, 2016, 12:29 PM
Love it.  I'll be watching this closely.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Hanjo Solba on Jun 23, 2016, 12:44 PM
That's awesome!  Great design! Got to love 3D printers
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: raider fett on Jun 23, 2016, 12:47 PM
That looks fantastic.  :o
What resolution did you print at?
Is that 300x300 bed? Looks like a solid machine.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jun 23, 2016, 01:51 PM
That looks fantastic.  :o
What resolution did you print at?
Is that 300x300 bed? Looks like a solid machine.


I printed at their speed setting  8) the layer height was 2.5mm. When I printed the little breathers on the face (not in picture) I printed at .05mm so that I had not lines in the print. Whit the acceptation of my 'Y' wobble issue which I am chasing down the cause it is a fantastic machine.


Good lord that is amazing.

If you decide to mold that and make production copies, let us ALL know. That bucket is amazing.

Seriously considering it.... I have about 15 years of resin casting experience, problem is, I dislike casting.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Jonathan Rudy on Jun 23, 2016, 02:34 PM
Seriously considering it....
If you are considering it, I would recommend contacting the app team and seeing what era the helmet would fall in. NME Props made an amazing helmet and conferred with the app team before making the helmet available to the public. If the app team approves and stamps an era on it, I think you could sell as many of those as you wanted to make!

... Dibs on the first one! :)
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jun 23, 2016, 04:54 PM
Good suggestion. I checked before I started the project http://mandalorianmercs.org/forum/index.php?topic=92867.msg1358382#msg1358382
Ralin stated it was Late Crusade and usable, whether this means it is good for sale to the masses as Late Crusade should probably be confirmed, just to be 100%.

I sent Railin a PM for the double check...
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Niabi on Jun 26, 2016, 03:05 AM
:O



mmmmmm 3D printing......

Smexy as hell !
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jun 27, 2016, 07:11 AM
So…. Then this happened… http://mandalorianmercs.org/forum/index.php?topic=116681.0

A diversion from priming and sanding... a bit of CAD work on a blaster.

Looks like the helmet got the nod! Yippie!!! they are still looking at the armor, I sent over some game related info to help, fingers crossed they give a nod to the armor as well.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: EranAnn on Jun 28, 2016, 01:31 PM
THAT IS NEAT! :D
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Briks on Jun 28, 2016, 02:19 PM
I'm predicting that armor in your first pic is acceptable as it resembles clan varad armor.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jun 28, 2016, 04:28 PM
I'm predicting that armor in your first pic is acceptable as it resembles clan varad armor.

Fingers crossed.... I sent them over the links to Clan Varad and the Fire Commando, which uses the same armor and helm (minus the antenna on the helmet) Ultimately it is their call but considering the armor is labeled as "Mandalorian Fire Commando" I feel pretty good at its chances.

Granted I am using different leg armor, gloves and belt in the first shot.

Fire Commando:  https://swtor.jedipedia.net/en/npc/mandalorian-fire-commando Although I do take offence in being called "mandalorian_raiders.​trash.​" :P
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jun 28, 2016, 04:33 PM
The basics are all taken care of, now I am just left to nitpick at some troubled areas and difficult spots.

I blue tacked everything in place so items like the mic. tips are not positioned exactly right… but you get the idea.


(https://3.bp.blogspot.com/-PD6fJTr4MN8/V3LeLzxL35I/AAAAAAAAEus/1k_eOmOt_683SzOKxaMpaYgxBnGc8B-sACLcB/s1600/1.jpg)

(https://4.bp.blogspot.com/-B2iUdbtazNE/V3LeL8kbOqI/AAAAAAAAEu0/8TsHMHyncHw9h-owUTbDKkgoXL5AByzcgCLcB/s1600/2.jpg)

(https://3.bp.blogspot.com/-8UEbKSMJod4/V3LeLzh_3kI/AAAAAAAAEuw/vlBZTVQFAcs6N3QqFfVgeZFZDQOEDyW5ACLcB/s1600/3.jpg)
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Den Barren on Jun 28, 2016, 04:38 PM
That is simply beautiful vod!
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jun 28, 2016, 04:40 PM
That is simply beautiful vod!

Thank you brother... much appreciated!
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Jonathan Rudy on Jun 28, 2016, 06:47 PM
That is simply beautiful vod!
What he said. Truly a thing of beauty.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Zeafus on Jun 29, 2016, 10:01 AM
Oh Mylanta I want that bucket. It is amazing Vod.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jun 29, 2016, 07:31 PM
Thanks guys, When I started the modeling and printing I was not looking at casting it. It can still be done but I need to reprint the ears as two parts for each side. The cutouts would be an issue when it comes to the mold... it could be done as is but the mold would tear out much sooner and getting good casts of those parts would likely be more difficult as the alignment of the mold halves would be crucial.

Guess I need to reprint those :P
 
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Torolf Goran on Jun 29, 2016, 08:36 PM
That helmet is amazing!
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jun 30, 2016, 02:17 PM
Just got confirmation, the body armor is good to go for Late Crusade! WOOOOOT!

Time to get working on that.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Den Barren on Jun 30, 2016, 02:29 PM
Sweet vod! More awesome work on the way!
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Jonathan Rudy on Jul 01, 2016, 09:19 AM
Just got confirmation, the body armor is good to go for Late Crusade! WOOOOOT!

Time to get working on that.
Grats!!

I was looking over your first pics of the concept you are doing to see if I could help you get ready for the rest of the build. The tubes above the waist that wrap around to your kidneys and then feed into the backpack look like they would get in the way of your mobility. I don't know what you have in mind for that part, or if you're going to skip that and go a more traditional girth belt / separate backpack or backplate. Looking at the concepts, if you want to be faithful to the suit in the picture, I would recommend slapping together a quick prototype mock up from scratch materials just to see if you can move around efficiently without crashing into the tubes all the time. It looks like serious modifications would be required to make it comfortable to troop in for any length of time.

Just my 2 cents. :)
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jul 01, 2016, 01:31 PM
Grats!!

I was looking over your first pics of the concept you are doing to see if I could help you get ready for the rest of the build. The tubes above the waist that wrap around to your kidneys and then feed into the backpack look like they would get in the way of your mobility. I don't know what you have in mind for that part, or if you're going to skip that and go a more traditional girth belt / separate backpack or backplate. Looking at the concepts, if you want to be faithful to the suit in the picture, I would recommend slapping together a quick prototype mock up from scratch materials just to see if you can move around efficiently without crashing into the tubes all the time. It looks like serious modifications would be required to make it comfortable to troop in for any length of time.

Just my 2 cents. :)

Thank you for the recommendations!

I agree, its going to need to be broken up where it can be. I was thinking about hiding the first lamination/articulation point just under the tube. the next under the belt and a separate cod. The back can be broken up the same way with possibly one more lame under the pack. Granted this is not the 'ideal' location but at least if I want to remain faithful, I do have some locations to look at. Honestly I dislike the tube as it does not look like it serves any real world purpose but it does give a place to hide a lamination, I will cheat the tube a bit by using a fairly flexible material and by not giving it its full diameter where it meats the waist. By doing that, I can pull it in a little tighter to my body and have it a tad more comfortable for my arms when the drop to a natural position... but I still imagine anything sitting there will be a pain.

One thought I had was using a very high durometer rubber and cast the final armor from even if it is just the waist section.. under the tubes down to the belt, just to give additional flex. Something like smooth-On task 13 or another semi-rigid rubber or Urethane.

I used to build plate armor and fight in the SCA so I feel pretty comfortable with being able to articulate this with webbing to limit travel, but I agree, it is going to need some attention and thought to keep it workable and comfortable.

Cheers!
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jul 09, 2016, 05:26 AM
Last week I got some time to start on the armor, I think I have about 25-30 hours on it so far and a few more parts to get through. The gloves, foot armor grenades and a few other items are just rough-ins and I would like to go back and revisit a few components to add details that are still lacking.

I, unfortunately do not possess the same physique as the 3d game model who likely has a 52” chest and a 28” waist  :P  So I needed to deviate on the proportions from the in game model.

I needed to create a fairly accurate representation of my true build. I did this by putting on my cycling shorts and top and having my better half take some pics as I posed front and side. As I know my height, I placed the images of myself as a wallpaper in the CAD program and went about making a 3d model of myself and then scaling it to the correct height. I will spare you the gory shots of the potato with legs that is me…

The best way to help with the proportions issue is to bulk out other areas of the armor… the arms, shoulders and legs so that the proportions look a little better than if I had form fitting armor in these areas. What you see here is a fairly accurate representation of the overall form, mass vs. height.

Still much work to be done but I am enjoying the progress….
(https://3.bp.blogspot.com/-BrI7kPjpeiE/V4C_NUQXqpI/AAAAAAAAEv4/lZwUah8pkxQIVslIxPoeGjf5VyCG79TWQCLcB/s1600/body%2Barmor%2B1.jpg)

(https://4.bp.blogspot.com/-XM3Oi1qpwfM/V4C_NgV8g0I/AAAAAAAAEv8/-8Gsy0YG5r8wOzjxWqcPCGABycEdhQfvwCLcB/s1600/body%2Barmor%2B2.jpg)
(https://3.bp.blogspot.com/-HB1afftJJyg/V4C_NeHcvZI/AAAAAAAAEv0/9dy5Ks9f3cgtYdeCO1XgXB__N-TsngSHwCLcB/s1600/body%2Barmor%2B3.jpg)

(https://4.bp.blogspot.com/--oLsr5G5clA/V4C_N53QH4I/AAAAAAAAEwE/89xMedTU_h0LLPiG_NyP9_cs8qcvgRRxQCLcB/s1600/body%2Barmor%2B4.jpg)
(https://4.bp.blogspot.com/-edn9qjhLoWc/V4C_N_wHXxI/AAAAAAAAEwA/1DBKNZZLXi8Wly42-I7_pR-jnuJKr5zyQCLcB/s1600/body%2Barmor%2B5.jpg)

(https://1.bp.blogspot.com/-zNoz9BUnAOw/V4C_OGTZAZI/AAAAAAAAEwI/JTswb86ZPicEod3ehmKX-cWI1E3S2bHiQCLcB/s1600/body%2Barmor%2B6.jpg)
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: aforklikeutensil on Jul 09, 2016, 08:23 AM

Still much work to be done but I am enjoying the progress….


Me, too!  Love see this come to life.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Jonathan Rudy on Jul 10, 2016, 10:08 AM
I like what you did for the waist. The tubes are still quite prominent but at the same time don't look like they'll get in the way.
I am going for Heavy Assault Brigade (finally got approved yesterday for OM) and my thigh plates that I currently have are about that size. As Mandalore the Uniter told me when he was here, "armor pinch is real". I would recommend anticipating having to trim down the pieces a little once you actually get them cast and fitted. Also, my   thigh armor slips while walking. Currently there are just 3 elastic straps. Velcro will be needed to keep the thigh plate from sliding down. I had crescent shaped bruises on the tops of both of my knees after about an hour of trooping in it. Ew.

Looks amazing and I hope it is as much fun to make as it is to watch it being made!
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jul 10, 2016, 12:36 PM
Thank you aforklikeutensil!

I was afraid that making the design fit me was going to ruin it... It came out OK so I am pleased. I put myself on a strict diet and split the chest armor up in a manner to allow me to easily adjust the girth, I hope to tighten up the waist section a bit over time.



Thanks Jonathan!

Yeah, no doubt... the legs will be an issue, they will need to be suspended on straps from a waist belt. My metal SCA leg harness uses a leather strap and belt setup but I may go with a nylon strap for this, it would be more flexible than the leather. I saw Mynock did something similar http://mynocksden.com/projects/sith-acolyte/sith-acolyte-leg-armor/sith-acolyte-thigh-plates.html But I will need to do away with the clips or hide them.

Indeed armor bite is real :P My metal leg harness was cut too high so I used to get bit right in the soft part of the inner thigh where the leg and pelvis meet OUCH!

Here is my plan..as such, I will float the legs away from my body with a mix of HDF and MDF foam, the leg openings have about 1/2-3/4" extra distance from my legs in any one direction. I think the trick will be to find a foam dense enough to keep them from colliding. I have never done this before so there will be some trail and error... fingers crossed it works out. My other option is to cast that 'rim' area in a vey flexible resin let it partially set in the mold and cast the middle section while it is still tacky and can still bond to the next layer. I was actually planning on doing this with the waist section as well, just to give some flex. I have some material samples from smooth-on and a couple of resins selected.

Who knows if all that will work but it will be fun to experiment a bit with materials :)

I think my next decision will be whether or not to print the armor in a cheap material such as PLA and pull a mold or print to wear with two specific much more expensive nylon filaments. The Nylon is tough as hell as long as the temp is correct and the layer bond is good and it has some flex, one of the nylons has quite a bit of flex, more like a semi rigid rubber.  Either way, I will likely need to find an automotive primer that is used on rubber bumpers and use primarily latex or other more flexible paints.

Decisions, decisions...


Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: jedisalamander on Jul 10, 2016, 05:31 PM
I think my next decision will be whether or not to print the armor in a cheap material such as PLA and pull a mold or print to wear with two specific much more expensive nylon filaments. The Nylon is tough as hell as long as the temp is correct and the layer bond is good and it has some flex, one of the nylons has quite a bit of flex, more like a semi rigid rubber.  Either way, I will likely need to find an automotive primer that is used on rubber bumpers and use primarily latex or other more flexible paints.

Decisions, decisions...
I've been told ABS is better for prop and armor making because it is less brittle and costs the same
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jul 10, 2016, 06:12 PM
ABS is pretty tough for sure but not as tough as Nylon.

I have printed ABS and its great... but you can drop or throw the part on the ground and if it has too much mass or weak spots, it will shatter.

It is more rigid than nylon (stiffer-harder to flex) but more prone to break. Nylon has better layer adhesion which is where most parts fail and the flex without breaking is insane... You can bend Nylon back on itself and for the most pat it simply springs back. ABS would snap if you tried that. Where ABS shines is vapor smoothing, or gluing using Acetone... Nylon needs to be welded as there are no suitable solvents that work as well. Welding is pretty simple. I have a large flat tip for my soldering iron and you simply use it to cut a V channel between the parts and the same filament you printed with to act as a welding rod. Just takes a bit of time but it is far stronger than gluing, so strong you parts will fail in other places before breaking the weld.

Both Nylon and ABS are prone to warp or lift off the print bed, neither does well with bridging or unsupported large overhangs. Nylon is very expensive...

If you need a very rigid part, Nylon would not be a good fit but if you do not mind or desire a bit of flex, it is a very solid choice.

This is a pretty good example.

ABS: https://www.youtube.com/watch?v=bmgSojocJ3c
Nylon: https://www.youtube.com/watch?v=8_pt_05BqYk
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Carid Vhett on Jul 13, 2016, 02:36 AM
Valkir, this is in response to your posts on the 11. Please refrain from double posting. In the future please use the edit button to add to the post.

Double posting is in breach of the forum rules that can be found here http://mandalorianmercs.org/forum/index.php?topic=84.0

Specifically rule 3.3
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jul 13, 2016, 04:25 PM
Valkir, this is in response to your posts on the 11. Please refrain from double posting. In the future please use the edit button to add to the post.

Double posting is in breach of the forum rules that can be found here http://mandalorianmercs.org/forum/index.php?topic=84.0

Specifically rule 3.3

Gotcha... folded the two posts together.


All the major parts have now been roughed in, now I go back and start adding details. Unfortunately, this armor is not in any of the high quality teasers or introduction videos where they add a slew of new details to the armor… such as they did for Shea Vizsla and a few other designs, so I do not have the cinematic quality references to bounce off of.

I started detailing the right arm first. As the helmet does not have a range finder/target tracker I decided to add an arm mounted unit, next to it is either a plasma torch for cutting bulkheads or a laser or flamer… guess it depends on if I go with a Brigade at some point and what the requirements are.

(https://2.bp.blogspot.com/-CDG0UuGs7hc/V4ashQpFZlI/AAAAAAAAEws/JiGM2hIHRxojSsqmzeJfo5Sv5z8K-9k2gCLcB/s1600/Right%2Barm%2BWIP1.jpg)

(https://1.bp.blogspot.com/-JkWhoAtlosM/V4ashilu3DI/AAAAAAAAEww/hRQPUM6a--AAcXVYYdMV_85lzMRUQhMggCLcB/s1600/Right%2Barm%2BWIP2.jpg)

(https://3.bp.blogspot.com/-BZoTml8EjU4/V4ashgXFv_I/AAAAAAAAEw0/Nk1lsDxBiqkwCWUCFa0nw_y_HPHClF5GQCLcB/s1600/Right%2Barm%2BWIP3.jpg)

The left arm…. Hrmmm, not sure what I will do. What I have in these shots is the typical SWTOR flamer mount with a large angular cover. It is very SWTOR Mando but I am not in love with the design.

(https://2.bp.blogspot.com/-QUUJYKVJYjs/V4ashLMweNI/AAAAAAAAEwg/QD9dXcF1ukoZ4tscMD7gP5NDbFpPTswcgCLcB/s1600/Left%2Barm%2BWIP1.jpg)

(https://3.bp.blogspot.com/-NEEol56e8E0/V4ashObS3eI/AAAAAAAAEwY/EBzRLDe4kmUoZ8-mhnUaqpoqthWZlzdngCLcB/s1600/Left%2Barm%2BWIP2.jpg)

(https://2.bp.blogspot.com/-HDW0HcH65wQ/V4ashCgrdgI/AAAAAAAAEwc/rCvDicBQgfoMOguNu9QUg56xOQmAdJLZgCLcB/s1600/Left%2Barm%2BWIP3.jpg)

Here are a couple of shots of that is under the cover…

(https://4.bp.blogspot.com/-qOG34L7tEuk/V4ashZpM5PI/AAAAAAAAEwk/4r5eSKQjbqsWqaJXjvQqMeZu3vfOv4dLwCLcB/s1600/Left%2Barm%2BWIP4.jpg)

(https://1.bp.blogspot.com/-A5TIpXt6H4E/V4ashbuiKyI/AAAAAAAAEwo/-oseBB6solsbwNVq5M8c7C2oAQIepIKPgCLcB/s1600/Left%2Barm%2BWIP5.jpg)


I could just as easily mirror the left arm to the right, skip the flamer (or whatever it turns out to be) and it would be good to go for the Fire Commando design that is found on the SWTOR site.

What do you think? I really could use some feedback as I am torn on what to do with that left arm.
If you have an opinion or suggestion, please chime in!


Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Den Barren on Jul 13, 2016, 05:58 PM
I love it vod! What do you use for the modeling and is it easy to use? I'd like to model a few things for printing and pepakura. :)
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jul 13, 2016, 06:05 PM
I love it vod! What do you use for the modeling and is it easy to use? I'd like to model a few things for printing and pepakura. :)

Heya Den,

What you see is modeled in Rhino, it is a NURBS modeler rather than a polygonal modeler. Easy to use? not at first, all 3d software has a learning curve. You can expect to be frustrated for a bit. My best advice would be pick up a free download such as milkshape or another poly modeler and watch a bunch of youtube videos that teach the basics... You will be scratching your head for a while but just keep pushing and it will click for you at some point.

Check with the people on the pepakura site for their advice, there may be software that they recommend for that app.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Den Barren on Jul 13, 2016, 06:23 PM
Heya Den,

What you see is modeled in Rhino, it is a NURBS modeler rather than a polygonal modeler. Easy to use? not at first, all 3d software has a learning curve. You can expect to be frustrated for a bit. My best advice would be pick up a free download such as milkshape or another poly modeler and watch a bunch of youtube videos that teach the basics... You will be scratching your head for a while but just keep pushing and it will click for you at some point.

Check with the people on the pepakura site for their advice, there may be software that they recommend for that app.

Ok! Thanks vod. I'll look into the milkshake. :) I understand the blender modeling program a little(VERY little). Is it similar, or would you say it's harder?
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jul 13, 2016, 07:21 PM
Ok! Thanks vod. I'll look into the milkshake. :) I understand the blender modeling program a little(VERY little). Is it similar, or would you say it's harder?

Blender is also a good start... I would say try both and see if one makes more sense than the other. It comes down to what you like in the menu layout. I use Zbrush quite a bit for organic models but I had a hard time at first with their menu controls as they are not like anything ells in the CAD arena but Zbrush also does things almost all other modelers cannot.  Do not look at Zbrush for your application, it is not a good fit as it lacks many CAD features that you will need. such as real world scales, etc.

Seriously, I would hit up people who are using the Pepakura and see what they think the best program would be and go from there.


_________________________________________________ _________________________________________________ ________________



This will likely be the last time I have all the components assembled into a single model. This is my last look at the components as a whole and tweak them for scaling and proportion so that the completed armor looks good as a whole.

I pulled in the 3d model of myself and started adjusting the individual components for scale, attempting to make the overall representation as slim as possible while still retaining the more desirable proportions. I narrowed the leg armor, arm armor, chest and shoulders as much as I could and added a few minor tweaks to better fit my body.

Here are the final proportions of the armor.

(https://4.bp.blogspot.com/-c6DeUZIhdP4/V4bk1TY465I/AAAAAAAAExI/uq5Q1WunlP4qq3PL53N7KOJfBee9iYwHQCLcB/s1600/tweak%2B1.jpg)

(https://4.bp.blogspot.com/-gd4VP1VsrcQ/V4bk1e1FHII/AAAAAAAAExE/PBN7UFt-RHkcb8UR0tMZHfh7DqXiW37AACLcB/s1600/tweak%2B2.jpg)
(https://3.bp.blogspot.com/-aHB81i8a7h8/V4bk1Tqcp2I/AAAAAAAAExM/lqPnDGyw-8Axqa6IyY9Gr86LOmaz0VepQCLcB/s1600/tweak%2B3.jpg)
(https://4.bp.blogspot.com/-9OQPNGqSQQk/V4bk1ovBKOI/AAAAAAAAExQ/bXfiiMzkZDUieSgewBE2HE-FHMp2V2AVQCLcB/s1600/tweak%2B4.jpg)

(https://3.bp.blogspot.com/-oR9lgYWSQvc/V4bk1pncn7I/AAAAAAAAExU/R7OYhKgZzcItsT56ljJeV0gcovmB_L0KgCLcB/s1600/tweak%2B5.jpg)

(https://3.bp.blogspot.com/-wOi9Ey9qU9w/V4bk1-GJtcI/AAAAAAAAExY/44RlBIoMWFI6_9it4lYpzHS2ShnHpMlUACLcB/s1600/tweak%2B6.jpg)

(https://2.bp.blogspot.com/-9L8DdZZReQo/V4bk1_-gEBI/AAAAAAAAExc/V9t1WHCRAz0rit3QUKeF1ZfH6zHfg1yZwCLcB/s1600/tweak%2B7.jpg)

(https://3.bp.blogspot.com/-8iQb1TiiZHQ/V4bk123Nu6I/AAAAAAAAExg/9_fIgJ2Lxl4Vz4eutkHuP9PTLCWwzHIdwCLcB/s1600/tweak%2B8.jpg)

It is far too difficult to work on individual components while they are on the model and posed in various angles. The next step is to take each component and lay them out in orthographic views and begin detailing them as it seems appropriate and splitting them for assembly (how you would get into them, i.e. front and back leg halves) and laying them out for print.

Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Jul 19, 2016, 10:34 PM
Here we have a bit of work completed on the legs.


Working on details can be tricky when your model only has a 1/8" shell... I need to backfill behind any in-cut details to keep the thickness uniform, I also need to make sure I am not adding too much thickness in some areas so that I can keep a good about of flex in areas lie the lower leg where in meets the foot.
 
(https://1.bp.blogspot.com/-qxXz6wv8A8k/V47hpT2DxRI/AAAAAAAAEx0/3thJvPbRx5Y52SVXT-vm8JdBqs3btX3sQCLcB/s1600/leg.jpg)

Here are some shots with a bit of color added to help show some of the surface detail.

(https://2.bp.blogspot.com/-IO1POUdkkJI/V47hp6hdDTI/AAAAAAAAEx8/5ujTnzEOcyYXFge-h0o2TYIZRr5oSCHVwCLcB/s1600/leg2.jpg)

(https://3.bp.blogspot.com/-VbZSz-MMNs8/V47hpddjExI/AAAAAAAAEx4/a4UmFSwZGgsX2mnGY-65jxSADJeQJgzcgCLcB/s1600/Leg3.jpg)

(https://2.bp.blogspot.com/-pueQUMeK_vs/V47hp58nxMI/AAAAAAAAEyA/mOMv_bwkhGk9oVoxr-NirKwdRPY_JmOwQCLcB/s1600/leg4.jpg)

Now off to work on the arms and chest….
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Taakur Beroya on Jul 19, 2016, 10:52 PM
You are an artist vod, these models are amazing
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Den Barren on Jul 19, 2016, 10:54 PM
Can't wait to see everything put together vod!
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Niyic on Jul 23, 2016, 07:36 PM
Very nice surfacing work. :)
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Zaeth Grak on Jul 26, 2016, 12:43 PM
I will be following this build with great interest. I always wanted to attempt 3D printing, I just don't have the access to a printer or the ability to get one as of this point in time. Great, great work, vod! Good luck with the rest.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Valkir on Aug 11, 2016, 07:18 PM
Thanks Vode!

I just started printing the legs... this is going to take a while :P

I settled on a filament for the lower legs... going with Taulman Bridge Nylon because it has some flex and crazy good layer bonding. The problem with Nylon is that it is a pain to print and absorbs moisture... eight hours in the oven at 170 looks like it did the trick to dry it out.

If you look at the lower leg, you will not see a front and back half, it has a hidden split under the detail in the back, with the flex Nylon gives it will allow me to slip my foot in as it flexes and it will spring right back to shape. Pretty cool.

I will post some update shots when the print is complete.


I have been working on another weapon while the printer does its job, you can see it in my signature (last link) if you are so inclined.

Cheers!
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Evren Jaira on Aug 30, 2016, 10:18 PM
I'm in love with the Shae Vizla/Hunter's Exalted bucket! I'm trying to print one myself but the file I have is converted from a Pepakura file and the details arent very good. This looks incredible! Fantastic job!
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Kol Varek on Sep 01, 2016, 07:28 PM
I am following this with a tremendous interest. 3D printing is so promising for mercs who know the ins and outs, and I think this is showing amazing potential!!
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Ty'renn Argos on Oct 03, 2016, 03:47 AM
Posting so I get updates on this.
Incredible work vod!!
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: Berit Haran on Oct 28, 2016, 05:19 PM
This is some crazy work, vod! I really love the helmet design...
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: archester on Apr 29, 2020, 11:27 AM
Astonishing print and design. I've recently had the chance to review a Raise 3D Pro Plus (https://top3dshop.com/blog/raise3d-pro-2-plus-3d-printer-review) and searched for any related content here to see if anyone has ever used it to print some cool stuff. And, guy, your helmet turned out great.

I'm really amazed by the build quality of the printer (including the top-notch touchscreen!) as well as its accuracy. No wonder that the brand success is skyrocketing.
Title: Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
Post by: YellowGhost1812 on Jun 29, 2021, 04:55 PM
Hello,

How much would it cost to make one of these to be made for someone for them to wear>? I am looking for back options because I bought an armor kit and it came out nice but then found out this club is legit but they don't accept Eva foam armor kits. So I am looking at redoing it right now but also having back options just in case. the only thing that is 3D PRINTED is my helmet.

from George