ODST foam armor and 3D printed helmet: Full completed build!

[jakemisra]

Hey everyone! Long time lurker and first time poster. I just wanted to show off my ODST I've been working on over the last 6 months. My brother and I hit crunch time to have the armor ready for C2E2 in Chicago at the beginning of summer, and then crunch time again to hit Wizard World Comic Con just last weekend. The foam armor patterns were all off Andrew DFT's YouTube channel, and then I pulled the helmet 3D file from Thingiverse. Full disclosure: we had access to a full machine shop, belt sanders, paint booth, etc. Definitely made the process much easier. Enjoy!

Very early pictures of the first foam parts


The straps on the arm are made out of the middle section of cardboard


First coats of plastidip


Bought some toys


Very lucky to have access to a paintbooth. Did some





Rustoleum hammer paint is so nice!



Didn't take a lot of pictures in between, but it was maybe 3-4 passes on finishing.


Back to armor, before dip

After dip!


Never skip leg day.





I don't know how to rotate images... But here's some damage getting applied


Made a stencil on a piece of a Dunkin Donuts box, turned out okay but not nearly as nice as the end product (coming up down below)


Bringing them out for a spin!


Hoping Gunny doesn't see us drinking...


Sup Chief!


Okay so now that we did one con without the helmet, it was time to repair the costumes, fix some functional stuff, and add more props: including a helmet!
Back to the grindstone...

First of 12 parts (per helmet) that I 3D printed.


Some parts with fun supports on them


(I reached the post limit, will continue below)

 

[jakemisra]

Some close ups. Those seams give us a lot of trouble later.

Printed! 350 hours of printing.

So 700 hours of 3D printing for both...

Now lots of Bondo and sanding.

After the lamest version of "vacuforming," we had some lenses.

Used iDye Poly black fabric dye for both of the lenses. Kept at 145 degrees F, they dye in like 10 minutes.

Now for the fun stuff. I have a friend that owns a printing shop, and he hooked it up with all custom decals for the whole costume.

3D printed stuff

I think I reached the limit again

 

[jakemisra]

I'm hosting the rest on imgur because upload was giving me issues. Here's some finished stuff!

Found Chief again!

Let me know what you think!

 

[ArmoredAmir]

Its so pretty. You guys did an amazing job on those suits! Well done Helljumper.

 

[jakemisra]

Thanks so much! This was our first build too. Unfortunately my brother is tapping out. He's going to make this costume better but said he wouldn't do another one this decade.

Me on the other hand, there will be more to come!