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.
I first modeled the helmet in high resolution in Maya, using the game asset as reference.
I then 3d printed the smaller parts myself with my Ultimaker 1, while the bigger parts were sent to Shapeways.
Each part had to be painted, filled, sanded multiple times, until very smooth.
Then came the molding part, using silicon. Most molds are made in 2 parts, using clay to make negatives. Some are poured-in, some are brushed-on.
When the molds are done, I cast with resin. Some parts are hollow, some are solid.
The visor was molded with clear plastic, using a small vacuum forming machine I built specifically for that purpose.
The final model was painted using Molotow spray paint, generally used for street art.