Genji's helmet

So this is my big project I have been work on and off for about a year. This is Genji's helmet replica. The goal was to learn how to make practical props, including molds in silicone and casting with resin.

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This is my (almost) finished Genji's helmet. Scroll down to see the progress

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This is the 3D model I made for 3d-printing, in maya

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Quick render test, done with substance painter and arnold

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another 3d render

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first printed part, exciting

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after a first round of primer, filler and sanding

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rinse and repeat, until super smooth. I alternate red and grey primers to see the layers when sanding. And red looks cooler

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second part printed

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The big bucket is done. It's heavy, even though I made it as thin as I could

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All the part are now printed

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Trying to get an idea of what it will look like. It's big!

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Preping the jaw, using various fillers and primers

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Progress on the helmet. You can see the primer left an ugly drip, but no worry, we'll sand it away

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All the small parts are almost done now. They don't look smooth but...

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A quick coat of primer and all smooth shiny

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Final coat on the jaw

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Same on the helmet, all smooth and clean

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Waxing before molding, to add an extra layer of smoothness

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After buffing, all shinny, ready to mold

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First mold. This one was a big mistake, this part was way too big for a traditional poor-in mold.

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For the other parts, I created brushed-on mold. Very messy but more practical for big objects and use a lot less silicone

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My garage was a mess for a couple of months

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Making the mother mold, the hard shell that goes around the silicone mold, to keep its shape once emptied

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Popping the mother mold open

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Pulling the master out of the silicone mold. Super tight

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And it's out!

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First casting test. Not quiet there yet

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Starting doubting...

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Third time is the charm

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Casting the helmet!

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Unmolding...

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Yay!

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The jaw went much better

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Some holes in the back, no big deal, this won't be visible

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Casting the smaller parts was easy

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Starting the paintjob, 3 months later

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Here again, not everything went well

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When I pulled the masking tape, some of the paint came with it :(

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Don't know if you can see it but there is an ugly paint drip. So I have to sand and start over

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Getting there. Only needs the visor and the "scarf"

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Vaccum forming the visor with transparent plastic. I built a small vaccum forming machine just for that :)

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Cut and painted the visor with a semi transparent paint. You can't really see through it :S

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Almost done :)

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Lighting test, using an LED flashlight. I will mount a proper lighting system later, using LED strip or EL tape

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And there it is, finished, or almost. Needs some paint touch-ups here and there, but it's done overall

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Overwatch Genji's Helmet