Thickness is important, it provides stability to the final product which can be brittle when it is printed too thin. The first step, while the poly count was low, was to extrude the model inward to give the helmet thickness. The conversion process was easy, but because the pep file is meant for paper usage, it was relatively low resolution and had no thickness. With a full version that allows you to create files rather than just view, I exported the pepakura file as an OBJ which I could would with in Maya.
I had also purchased a copy of the Pepakura software. :)Īs I mentioned, I had gotten the pepakura helmet file from the RPF forum. Please credit the Replica Prop Forum and I, if you use! As I outline in Step Two, the build envelope of the printer that was used to produce this helmet was 10" x 14" x 8", so I had scaled the pieces to fit that and it is sort of a happy accident that it worked out. I've added separate zip files with OBJ and STL files of the Ironman helmet pieces for others to use. I took photos and screen caps along the way, but I may have missed a few steps that I'll just have to explain. This is my first instructable, but I wanted to share my process for anyone who has been interested in going this route. I had tried building the helmet with pepakura files produced by a member of the, but I found I did not have the time/patience/skill to sit and trim out hundreds of pieces of paper and reassemble them. Early last year, before The Avengers came out, I approached the rapid prototyping department at my company and asked if they would be able to help me produce a replica Ironman helmet.
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