Iron Man Helmet

Costumes have always been a good source of entertainment in which people could express themselves and show off their creativity. People have always been innovating costumes from the beginning with white sheet ghosts to the complicated mechanisms of modern day cosplays. This iron man helmet strikes a fine balance between the simple and the complicated by using a cardboard helmet with a moving faceplate and voice changer.

Polycarbonate Lenses: https://www.amazon.com/BK219-BearKat-Polycarbonate-Safety-Non-Slip/dp/B001AEEKYC/ref=sr_1_1?keywords=crews%2Bbk3&qid=1639774798&sr=8-1&th=1

Arduino Uno: https://www.amazon.com/ELEGOO-Board-ATmega328P-ATMEGA16U2-Compliant/dp/B01EWOE0UU/ref=sr_1_1_sspa?crid=1NV3MT44B2VU2&keywords=arduino+uno&qid=1639774742&sprefix=Arduino%2Caps%2C194&sr=8-1-spons&psc=1&spLa=ZW5jcnlwdGVkUXVhbGlmaWVyPUExMUdCOVlDREU2Ulo3JmVuY3J5cHRlZElkPUEwNTYxNjU5T09OQkRGUEpNNFJEJmVuY3J5cHRlZEFkSWQ9QTA3NjU3MzYzRUlDRUkxN1k0NUdYJndpZGdldE5hbWU9c3BfYXRmJmFjdGlvbj1jbGlja1JlZGlyZWN0JmRvTm90TG9nQ2xpY2s9dHJ1ZQ==

Adafruit Waveshield: https://www.amazon.com/Adafruit-Wave-Shield-Arduino-Kit/dp/B00IQXZN9Q/ref=sr_1_1?keywords=adafruit+wave+shield&qid=1639774716&sr=8-1

Servo Motor: https://www.amazon.com/Micro-Servos-Helicopter-Airplane-Controls/dp/B07MLR1498/ref=asc_df_B07MLR1498/?tag=&linkCode=df0&hvadid=330396616558&hvpos=&hvnetw=g&hvrand=4830305628923559111&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9016165&hvtargid=pla-670000123095&ref=&adgrpid=66216311757&th=1

Cardboard

Felt Strips: https://www.amazon.com/Adhesive-Self-Stick-Polyester-Protecting-Furniture/dp/B08LG7S6P6/ref=sr_1_1_sspa?keywords=felt%2Bstrips&qid=1639774829&sr=8-1-spons&spLa=ZW5jcnlwdGVkUXVhbGlmaWVyPUFMTVFCNkU4Rk9HWUkmZW5jcnlwdGVkSWQ9QTAxODAwMDEzVlZLWVBXSlhKWjhWJmVuY3J5cHRlZEFkSWQ9QTAwNDk3NDkyMzhDTExBVEFDWVFFJndpZGdldE5hbWU9c3BfYXRmJmFjdGlvbj1jbGlja1JlZGlyZWN0JmRvTm90TG9nQ2xpY2s9dHJ1ZQ&th=1

Wires

Speaker: https://www.amazon.com/Uxcell-a15080600ux0275-Internal-Magnet-Speaker/dp/B0177ABRQ6/ref=sr_1_1?crid=2BIN5SH5SXKVQ&keywords=uxcell+speaker&qid=1639774899&sprefix=uxcell+spes%2Caps%2C182&sr=8-1

Soldering Iron

Hot Glue Gun

Resistors,

push-buttons

Using a cardboard sheet draw the outline for the iron man helmet with a marker before cutting out the shape, follow the guidelines set above to ensure a shape that will fit around your head comfortably on your head. Color to your liking, we chose a red and gold color reminiscent of iron man's color scheme but feel free to be creative!

For the faceplate cut it out in a similar shape to what is pictured above. Make sure the plate fits perfectly over the hole used for your face and that you will be comfortable with the mask closed and opened. At the top of the mask hot glue a hinge that fits into the servo motor to allow for open and close of the mask. Add strips of rubber/felt to make the mask sit more comfortably on your face.

One the servo motor is connected to the mask hot glue the servo motor to the top of the mask in a way that allows the mask to clamp over the top of the helmet comfortably and allows for free range movement of the mask. After ensuring that the mask fits properly to the helmet wire a push button according to the diagram above.

Program the push button according to the code above and after ensuring that it works upload it to your Arduino. The push button can be added to the side of the helmet in order to open and close the helmet's face plate in order to replicate that movie magic feel even better.

The voice modulator is a very fun technology that can be incorporated into the helmet. The voice modulator can change your voice to very high pitch and squeaky or very low and scary.Here is a link to download the code. Download the project code and files in Zip. It requires a lot of soldering and patience. If you don’t know how to solder, read the soldering section, and watch the video before attempting this part! 

The speaker used on this project is very small so that it fits on the helmet. This means it is cheap and doesn’t work well for the voice modulator. If you want the modulator to sound pristine with no static a bigger, higher quality speaker will be needed. 

Watch this tutorial on how to solder: 

Soldering Tutorial for Beginners: Five Easy Steps - YouTube 

After all of your hard work it's finally time to finalize your Iron man mask! Glue your push button to the side of the helmet where it would be easier to access and would look the most cool during helmet operation. attach the portable battery to the back of helmet next to the Arduino where it would be out of sight. Attach a strip of cardboard over the servo motor for aesthetic purposes. After that you have successfully made an iron man helmet, Congratulations! feel free to add your own artistic flair and really make it your own!

[1] “How to Use an Arduino with Linear Actuators,” Progressive Automations, https://www.progressiveautomations.com/blogs/how-to/how-to-use-an-arduino-with-linearactuators. (accessed September 7th , 2021].  

[2] “Stepper motor circuits,” Stepper Motor Circuits - Northwestern Mechatronics Wiki. [Online]. Available: http://hades.mech.northwestern.edu/index.php/Stepper_Motor_Circuits. [Accessed: 30-Aug-2021].     

[3] “JP h01101010 a - voice Modulation circuit the lens - free & open patent and Scholarly Search,” The Lens - Free & Open Patent and Scholarly Search. [Online]. Available: https://link.lens.org/BvfXjCtsiBh. [Accessed: 30-Aug-2021].    

[4] W. Y. Lee, N. Murli, N. Wahid, R. A. Hamid, and M. F. Othman, “Voice converter on Android” Journal of Physics: Conference Series, vol. 1049, p. 012082, 2018. doi: 10.1088/1742- 6596/1049/1/012082 

[5] Huston, Davin, “Semester Project Description” 

[6] “Finding Your Correct Hat Size: Instructions from Hats.com,” hats.com. [Online]. Available: https://www.hats.com/find-your-size. [Accessed: 08-Sep-2021]. 

[7] J. 21, “What power supply can I use with my Arduino board?,” Arduino Help Center. [Online]. Available: https://support.arduino.cc/hc/en-us/articles/360018922259-What-power-supply-can-I-use-with-my-Arduino-board-. [Accessed: 13-Sep-2021].  

[8] “Too loud, too long-learn about the factors affecting noise-induced hearing loss,” National Institute of Deafness and Other Communication Disorders. [Online]. Available: https://www.noisyplanet.nidcd.nih.gov/parents/too-loud-too-long. [Accessed: 13-Sep-2021]. 

[9] “Four ways to power up the Arduino Uno,” Technobyte, 04-Apr-2020. [Online]. Available:  https://technobyte.org/2016/07/power-up-the-arduino-uno/. [Accessed: 13-Sep-2021]. 

[10] “Saturday,” Comic, 23-Jul-2021. [Online]. Available: https://www.comic-con.org/cci/saturday.  [Accessed: 13-Sep-2021]. 

[11] B. Butterworth, “What Speaker Impedance Means and Why It Matters,” Lifewire, 13-Nov-2020.  [Online]. Available: https://www.lifewire.com/speaker-impedance-3134705. [Accessed: 22-Sep- 2021]. 

[12] A. Industries, “Adafruit Wave Shield for Arduino Kit,” adafruit industries blog RSS. [Online]. Available: https://www.adafruit.com/product/94. [Accessed: 13-Dec-2021].  

[13] “Arduino Uno REV3,” Arduino Online Shop. [Online]. Available: https://store-usa.arduino.cc/products/arduino-uno-rev3/?selectedStore=us. [Accessed: 13-Dec-2021].  

[14] “2820 Servo Motor,” 2820 Pololu Corporation | Motors, Solenoids, Driver Boards/Modules | DigiKey Marketplace. [Online]. Available: https://www.digikey.com/en/products/detail/pololu-corporation/2820/10450037?utm_adgroup=Motors%2C+Solenoids%2C+Driver+Boards%2FModules&utm_source=google&utm_medium=cpc&utm_campaign=Shopping_DK%2BSupplier_Pololu+Corporation&utm_term=&utm_content=Motors%2C+Solenoids%2C+Driver+Boards%2FModules&gclid=CjwKCAiA-9uNBhBTEiwAN3IlNHmVNqawQg4w_nA4kkLNy_a0aDzfC7zzn-NMrCh7LvYe5aPy5WCSNhoCcjsQAvD_BwE. [Accessed: 13-Dec-2021].  

[15] “Iron Man Mark 4 Helmet A4 & Letter Size PDF Template,” Etsy. [Online]. Available: https://www.etsy.com/in-en/listing/704630422/iron-man-mark-4-helmet-a4-letter-size. [Accessed: 25-Oct-2021].