3D Printed Iron Man Helmet
This 3D printed Iron Man helmet began as a Fusion 360 model, where I focused on accurate proportions, articulated faceplate geometry, and clean separation between printable components. During design, I added internal channels for wiring and defined mounting points for hinges and magnets, then iterated shell thickness and support locations to balance strength with reasonable print times. Complex curves around the jaw and visor led me to split the model into smaller sections, reducing warping and making support removal manageable on a standard FDM printer.
After printing, I devoted significant time to post-processing: progressive sanding to remove layer lines, gap-filling at seams, and multiple rounds of primer and wet sanding before applying color-matched metallic paints and a clear coat. I integrated LED eyes powered by a compact battery pack, routing the wiring through the pre-modeled channels and securing everything to maintain comfort, durability, and serviceability. The finished helmet demonstrates my end-to-end workflow—from CAD modeling and print tuning through finishing and basic electronics integration—mirroring the same iterative, problem-solving approach I use in robotics and other prototyping projects.
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