VH-01 Pegasus
I transformed a concept pilot helmet from the 80's anime “Macross” into a digital mockup before fabricating it as a physical, wearable prop. The final helmet is a resin cast that features padding and a flip down visor.
The helmet was designed in Autodesk Inventor using a combination of surface modeling and solid modeling. Challenges included interpretation of varying feature proportions due to the nature of the animation, without having access to source concept drawings.
Everything was designed around a 3D scan of my head to ensure proper fit. The resulting concept was prototyped out of sintered nylon by Shapeways.
Making it real
Technology allows for the hobbyist to engage in rapid prototyping using high accuracy sintered nylon prints. It is this democratization of technology that allow a digital asset to become tangible in a matter of weeks instead of months, which would have been the case just a few years ago.
The print was smoothed using automotive body filler and high build primer. Silicone molds were made from the finished master to produce resin replicas, which were then masked and painted
the 3D print was filled and sanded prior to molding.
Several layers of brush-on silicone were applied to produce the mold.
The helmet features a flip down visor