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 Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor

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Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
« Reply #45 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!

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Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
« Reply #46 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...



Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
« Reply #47 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

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Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
« Reply #48 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

Carid Vhett


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Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
« Reply #49 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

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Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
« Reply #50 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.







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.







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






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!



Den Barren


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Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
« Reply #51 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. :)

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Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
« Reply #52 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.

Den Barren


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Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
« Reply #53 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?

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Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
« Reply #54 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.


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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.















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.


Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
« Reply #55 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.
 


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







Now off to work on the arms and chest….

Taakur Beroya


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Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
« Reply #56 on: Jul 19, 2016, 10:52 PM »
You are an artist vod, these models are amazing

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Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
« Reply #57 on: Jul 19, 2016, 10:54 PM »
Can't wait to see everything put together vod!

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Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
« Reply #58 on: Jul 23, 2016, 07:36 PM »
Very nice surfacing work. :)

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Re: Valkir's WIP Late Crusade armor (SWTOR based) 3D printed armor
« Reply #59 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.

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