Timeline: 6 weeks
Over six weeks in May 2017, I was given the challenge to build two Andorian helmets, following a design concept drawing by Ray Lai. I used a mixture of NURBS surfacing and mesh modeling to create a model from which a set of 3D prints were made on a high resolution FDM printer. The design was subdivided to decrease the failure rate of the prints, while allowing for the extensive hand finishing typical of FDM printing. Once the helmet was glued up, we lined the interior with two courses of fibreglass to solidify the helmet. The eyes were vacuum formed PET-G over a 3D printed and polished buck.
One of the central constraints of helmet design is the easy removal and ventilation for the comfort of the actor, in this case Rainn Wilson playing Harry Mudd, a deceptive con-man fixated on attaining revenge over Captain Lorca. To accommodate this, we made the face of the helmet detachable via a set of magnets, relying on custom magnetic pin connectors to supply the 3 channels required for the RGB controllable eye lights. In addition to the lighting, there were CPU fans located in each ear which drew air in and out through a series of holes in the ear details increasing the comfort of the actor.