Mark 6 Iron Man Helmet

After my previous Iron Man suit project, I decided I wanted to make another with more advanced capabilities! This Instructable will teach you how to 3D Print and motorize the Mark 6 Iron Man Helmet.

Here is the list of supplies you will need to complete this project:

1. Adventurer 5M 3D Printer - $259
2. 2 Rolls of PLA filament - $30
3. Flexible Iron Man Light Up Eyes - $19
4. 2 MG90s Motors - $9
5. Helmet 3D Model - $29
6. Speakers - $8
7. Helmet Motorization Board - $60
8. Pliers (They come with printer)

Total Price With Printer: $414

Total Price Without Printer: $155

This might seem like a lot, but it will all be worth it!

Using Orca Slicer, do the following:

You will be importing the files purchased for the helmet, along with these files.

Each time you import a file, position it with you preferred settings, and then export the GCode for it.

Once you do that, you are done preparing the files!

You are now ready to print! This will be pretty quick on the Adventurer 5M, as it prints at 600mm/s!

1. Print the files one by one (You can print all of the files from the motorization kit at the same time)
2. If you would like to make the paint turn out better, you can sand the printed parts (Not the motorization kit parts)

This is the most fun part: Painting!

1. Mask off parts of the helmet one by one for each color (For bigger parts, use newspaper to save masking tape)
2. Paint the helmet using your choice of 2 colors (I chose navy blue and gold)
3. Wait 24 Hours for the paint to air out, and then apply 2 layers of clear coat spray paint

Are you ready for electronics? Here we go! I will give instructions on the process, but if you would like clear images or other information on it, you can open the PDF attached to the Thingiverse files you downloaded.

1. Put the motors into the printed motor holder
2. Attach the servos to their designated spots on the motorization board, and power it on, and then wait until the motors move to their closed position
3. Attached the 3d printed servo horn arms to the servos facing forward (The way that would face the face mask)
4. Screw in the servo horn arms onto the servos
5. Screw the faceplate bracket onto the ends of the 2 servos horn arms lightly so it can still rotate (In between the 2 of them)
6. Glue the servo holder onto the widows peak of the helmet (Make sure the arms are able to rotate over the widows peak without colliding with it)
7. Power the board again to send the servos to their home position, and then place the faceplate in the closed position (Tape it in place for now to hold it there)
8. Rotate the faceplate bracket around until it lays flat on the faceplate, and then glue it in place
9. Once the glue dries, test it out by touching the 2 input wires together to open and close the faceplate
10. Glue the eyes to the inside of the helmet with the textured side facing inward, and the wires pointing toward the middle of the faceplate, not the outside of it
11. Plug them into their designated pins on the board
12. Test the helmet again, to make sure the lights turn off and on when you open and close it
13. Plug the speaker into the speaker port of the board

You are now done!

Some other modifications you can do are:

1. Magnets to take on and off the back plate of the helmet
2. Solder your own switch onto the input wires to make it easier to open and close

Enjoy your new Iron Man Helmet!!!