Lego Imperial Storm Commando Helmet

Early prototypes from Shapeways (clear print) and Custom Color 3D Printing (color model), new versions will be printed soon with some adjustments. Piece fits perfectly on Lego heads, just not quite satisfied with how tall the overall piece is.

For my final project I decided the time had come to finally put everything I had learned in the 3D printing course to the test, and make a custom Lego Star Wars Imperial Storm Commando helmet based off of a 2009 Hasbro action figure I own.

Action figure used for reference
Circular sketch created to form the main cylinder that will be used to cut out space for a Lego head in the model.
Sketch used to form the top button for the body that will be used to cut out space for a Lego head. This will eventually form where the top of the Lego head connects to the helmet.
Circular sketch used to form the cylinder that will act as the foundation of the helmet piece. This was purposely made as a separate body as the previous two steps created a body that will act solely as a cutting tool when the model is finished.
Rectangular sketch created to form the main ridge going along the back and sides of the helmet. This was done by revolving the sketch 180 degrees.
Two rectangular sketches created halfway into the cylinder, these were extruded and then mirrored to form the basic shape of the sun visor.
Triangular sketch created on one side of the sun visor. This was used in an extruded cut to help further develop the shape of the sun visor; the resulting cut was then mirrored to the other side of the model.
Rectangular sketch created and then extruded outward towards the front of the helmet to complete the main ridge going along the back and sides. This feature was also mirrored to maintain symmetry. The top and bottom edges of the main ridge were filleted after this was done.
Ellipse sketch created to form the topmost rounded portion of the helmet, this sketch was then extruded and filleted to form that feature.
Rectangular sketch created pointing 45 degrees inward off of the inner edge of the sun visor meeting the cylinder. The sketch was extruded in two directions to begin forming the “face” of the helmet. The feature was then mirrored along the Z-axis
Rectangular sketch used in an extruded cut to form the air vents at the front faces of the main ridge. The resulting feature was then mirrored along the Z-axis
Sketch used in an extruded cut to form indented details on the sides of the helmet. The resulting feature was then mirrored along the Z-axis.
Sketch used in an extruded cut to create the side air vent details of the helmet. The resulting feature was then mirrored along the Z-axis.
Rectangular sketch used in an extruded cut to shave the angled extrusions to better fit the profile of the cylinder. The resulting feature was then mirrored along the Z-axis.
Another rectangular sketch used in an extruded cut to better fit the angled extrusions to the profile of the main cylinder. The resulting feature was then mirrored along the Z-axis.
Sketch used in an extruded cut to create a flat face pointing into the cylinder. The newly exposed face was extruded into the main cylinder in order to cleanly join the angled extrusion to the main cylinder, then the outermost edge of the angled extrusion was filleted for a cleaner look. The resulting features were then mirrored along the Z-axis.
Sketch created just inside the main cylinder to form the first profile for the loft that will become the “snout” of the helmet.
Sketch created further forward from the previous sketch to act as the second profile for a loft, this sketch and the previous one were then used in a loft to form the “snout”of the helmet.
Sketch used in an extruded cut to flatten the front of the “snout”
Sketch used in an extrusion going into the helmet in order to begin shaping the angled bottoms of the “face”of the helmet. The resulting feature was then mirrored along the Z-axis.
Sketch used in an extruded cut to form the outermost flattened areas on the “face” of the helmet. The resulting feature was then mirrored along the Z-axis.
Sketch used in an extruded cut to form the innermost flattened areas on the “face of the helmet” that are right next to the “snout”. The resulting feature was then mirrored along the Z-axis.
Sketch used in two upward extrusions to begin forming the ridges that will surround the visor of the helmet, the innermost of the two extrusions was initially created as a separate body for the next step.
Sketch used in an extruded cut on the new body to form the lower profile of the visor. This separate body and the other extrusion from the previous step were then mirrored along the Z-axis and then combined into the main body of the helmet.
Arc sketch used on the inside of the top of the sun visor in order to make the final extrusion needed to complete the visor of the helmet.
Sketch created on the bottom of one of the angled sections of the “face” in an extrusion that extended this part of the model further down. The resulting feature was then mirrored along the Z-axis.
Sketch used in an extruded cut to help further angle the bottom of the front of the helmet. The resulting feature was then mirrored along the Z-axis.
Small rectangular sketch used in extruded cut to clean up a couple edges from a previous extrusion that were sticking out of the “snout”.
Sketch used in an extruded cut to create the air vent details on the flattened spaces on each side of the “snout”. The resulting feature was then mirrored along the Z-axis.
Sketch used in an extruded cut to form indentations of the sides of the sun visor. The resulting feature was then mirrored along the Z-axis.
Sketch used in an extrusion to create split faces on the model that were then pushed in to form the rear indentations (these indentations are purposely off center as they are like this on the action figure).
Sketch used in an extruded cut to begin forming the indentations on the front of the “snout”.
Sketch used in an extrusion to create split faces on the model that were then pushed in to form the indentations just above the visor.
Final sketch used in an extrusion to create the vent details on the front of the “snout”. After this the edges along the visor were lightly filleted along with edges on the sides and top of the sun visor. The separate body created at the very beginning was also used in a combined cut that formed space for a Lego head, completing the helmet.
Images of the finished model in Fusion 360
Snapshot of the drawing showing model dimensions.

Print settings:

(final model will be printed by Shapeways inc, these are the settings used for a scaled up version printed on an FDM 3D printer)

Layer height: 0.2mm

Supports: zig-zag

Adhesion: none (no brim used)

Time for print: 6hrs 46mins

Filament usage: 76 grams

Infill: 18%

Link to scaled up model on Thingiverse: https://www.thingiverse.com/thing:4046764

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