I built a Gray Fox Helmet (Metal Gear Solid) over the course of seven months by combining parametric 3D modeling, SLS rapid prototyping, silicone molds and an AVR microcontroller to drive lights and servos. Continue reading below for details:
Head was scanned with autodesk ReMake
Parts were printed via www.shapeways.com
Microcontrollers and lights are from www.adafruit.com
Resins used include smoothcast 300 and Apoxacast 690 by www.smoothon.com
Silicones used include Moldstar 20T and Rebound 25, also by smoothon.
FAQ:
No, I won't make you a DJ helmet
No, I won't make a motorcycle helmet
No, the military certainly isn't interested in a flimsy cosplay helmet
No, a VR display doesn't fit, neither do tiny monitors or a HUD
No, I won't give you the 3D files
No, there's no pepakura file
No, I won't send you the code
Yes, I'm going to start working on the full suit now
Yes, I encourage you to consider becoming an engineer, and to experiment with 3D modeling software and programming.
Some resources for learning more:
Autodesk Fusion360: http://www.autodesk.com/products/fusion-360/overview
Microcontrollers and LEDS: https://learn.adafruit.com/
4 bar linkage: http://www.mekanizmalar.com/fourbar.html
