[Project] Homemade, FULL SIZE, Iron Man Helmet

[Robin]

About The Project I am currently working on a rather interesting project: a life-size Iron Man helmet. The helmet will be a full-size replica of the Mark 3 Iron Man armour that was created, used and destroyed in the original Iron Man (2008) movie. The helmet will be wearable and 3D printed. I will be 3D printing the whole helmet, which consists of a total of 11 parts separated over 10 print jobs. The total print time is an estimated 120 hours and 52 minutes, however, this does not take any failed prints into account. The expected total print time, including failed prints and software inaccuracies, is roughly 140 hours. The total print material costs will be roughly 13 euros (factoring in failures), the final weight will be 533 grams.

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Techniques The printer used for the job is a Creality CR-10S Pro, printing with 1.75mm FilRight Maker PLA. The printer has a print bed (aka total print size) of 300x300x400mm, which is rather large for a customer-grade 3D printer. The accuracy is 100 microns. I won't be painting it myself, a friend will do that for me. She'll most likely use an Airbush with metallic paint. Technical Details Printer: Creality CS-10S Pro Printable Size: 300x300x400 millimeters. Slicer (used to 'prepare' the 3D file for printing): Ultimaker Cura 4.1.0 Temperature: 200c extruder, 60c bed. Speed: 40mm/s, 20mm/s outer wall and initial layer Infill: 10% lines Nozzle size: 0.4mm Layer height: 0.12mm Support: Touching buildplate, 50° overhang

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Pictures, more coming as the project progresses.

Spoiler: show

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Part List

File/Object	Status	Weight (Grams)	Time (Hours:Minutes)
Back Top Shell	Print completed	56	11:12
Backplate	Print completed	38	8:50
Earpieces	Print completed	27	5:12
Faceplate Top	Print completed	56	13:23
Faceplate	Print completed	45	9:49
Helmet Top	Print completed	57	13:19
Jaw	Print completed	66	18:39
Left Sideplate	Print completed	59	13:34
Rear Main Plate	Print completed	70	14:57
Right Sideplate	Print completed	59	13:34

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Updates

Spoiler: show

Original post

Update 1: First Part Done!
The first part, the jaw, has been completed! While the first two attempts failed after the first 30 minutes, this time it finally succeeded. The total print time for this object was 18:39, a little under two hours over the estimated printing time.
Sadly the bottom of the chin and jawline area didn't turn out too well due to the large overhang, but luckily the spot isn't too visible and it looks like it can be fixed in the post-processing.
The main post has also been updated to increase readability.

Pictures above!

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Original post

Update 2: Face & Ears
After the Jaw was completed, I started printing the earpieces, these were really simple to print and didn't take long with a print time of 5 hours and 12 minutes for both.
The faceplate, was next and turned out really neat, I printed the top part overnight, which took 12 hours and 40 minutes. And the bottom part during the day, which took 13 hours and 23 minutes.
For the night, I will be printing the backplate, that way I can start another print before I leave for work tomorrow morning.

Faceplate picture above!

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Original post

Update 3: All Parts Printed
All of the parts have finished printing! All there's left is the paint.
I will hand over all parts to the girl that'll paint them in a week or something, I'll keep you lads updated!

Multiple pictures have been added to the main post

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Original post

Update 4: Painting process
It's been a while since I posted an update, so here it is!
The painting chick says it needs a couple more layers, so it might take a while for it to be finished.

Pictures have been added to the main post as well.

[Friday]

starting 2day?

[Robin]

starting 2day?

I have started yesterday evening, the first part (the jaw) is currently has 78% of the layers completed.

[Mastro]

Damn bro, sounds like a sick idea, gl

Are you planning on selling it someone?

[Robin]

Damn bro, sounds like a sick idea, gl

Are you planning on selling it someone?

Nope, I'm going to put it on display somewhere in my house.

[Friday]

What are you gonna do about the heating problems with the printer

[Robin]

What are you gonna do about the heating problems with the printer

Which problems exactly?

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I've added a part list and a picture of my cat discovering the printer to the post

[Milyn]

Nice cat

[Friday]

What are you gonna do about the heating problems with the printer

Which problems exactly?

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I've added a part list and a picture of my cat discovering the printer to the post

I get it now, so you're gonna print the parts one by one instead of for a full 130+ hours continuously.
I heard that 3d printers heat up pretty quick

[Robin]

What are you gonna do about the heating problems with the printer

Which problems exactly?

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I've added a part list and a picture of my cat discovering the printer to the post

I get it now, so you're gonna print the parts one by one instead of for a full 130+ hours continuously.
I heard that 3d printers heat up pretty quick

They print using heat, so yes they heat up as they're supposed to do that, this one can go up to 260c.
I've had zero issues with really long prints so far, nor I know that any would appear.