HOW TO MAKE a Motorized Iron Man helmet! - Mark 45 Tutorial and Flashforge AD5X showcase! - YouTube
Summary
This video provides a comprehensive tutorial on building a 3D printed, motorized Iron Man Mark 45 helmet. It covers scaling the helmet for a proper fit, 3D printing with various colored filaments, assembling the components, and integrating electronics. The tutorial details the process of coding and soldering onto a custom PCB, utilizing the Walsh3D 'Iron Man Servo Pro' kit for seamless motorized faceplate operation. It also showcases the Flashforge AD5X 3D printer and offers links to all necessary files, parts, and software for viewers to replicate the project.
Key Insights
Walsh3D's 'Iron Man Servo Pro' kit simplifies motorization.
The design features Walsh3D's 'Iron Man Servo Pro' all-in-one kit, which integrates the motorization system directly into the servo mount, eliminating the need for external support arms. This kit also allows for easy scaling of the helmet between 90% and 110% without modifications.
Optimal orientation and support painting for print quality.
Orienting parts like the main dome vertically minimizes the 'stairstepping' effect on curved surfaces, leading to a smoother finish. Support painting is used to precisely add supports only in necessary overhang areas (around 45°) and on the bottom lip of the faceplate for bed adhesion.
Zero servo arms when servos are in the closed position.
Before final installation, power the servos to ensure they move in the correct open/close direction. Once confirmed, screw the servo arms into place when the faceplate is in the closed position to accurately zero their orientation.
Sections
Introduction and Project Overview
Learn to build a 3D printed motorized Iron Man Mark 45 helmet.
The video guides viewers through the entire process of creating a motorized Iron Man helmet, specifically the Mark 45 model. This includes scaling the helmet to fit, 3D printing the parts, assembling them, and handling all the electronics from coding to final assembly.
PCB Way sponsorship and PCB ordering information.
The tutorial highlights the role of PCB Way as a sponsor, emphasizing their expertise in PCB manufacturing and 3D printing. A link is provided in the description for viewers to easily order the custom circuit board designed for this project.
Links to all necessary supplies provided in description.
All materials, tools, and components required for the build are linked in the video description. The presenter recommends watching the full video first before starting so that viewers understand when and how each component is used.
Mark 45 helmet model by Walsh 3D and VEC3D.
The specific Iron Man helmet design used in the tutorial is the Mark 45, modeled by Walsh 3D and VEC3D. The files for this model can be acquired from Wireframe 3D, a marketplace for 3D models, particularly those related to cosplay.
Walsh3D's 'Iron Man Servo Pro' kit simplifies motorization.
The design features Walsh3D's 'Iron Man Servo Pro' all-in-one kit, which integrates the motorization system directly into the servo mount, eliminating the need for external support arms. This kit also allows for easy scaling of the helmet between 90% and 110% without modifications.
Scaling and 3D Printing Preparation
Scale helmet parts using slicer software and head measurements.
To scale the helmet, essential parts like the dome, faceplate, and backplate are loaded into slicer software. A cross-section is used to take measurements, which are then compared to personal head measurements, possibly using 3D printed calipers. The scale is adjusted within a 90%-110% range, and a test print of the cross-section is recommended.
Flashforge AD5X 3D printer for high-quality prints.
The Flashforge AD5X is showcased as the printer used for this project. It features a 220x220x220mm build volume, Core XY motion system for high speeds (up to 600 mm/s), and a smart multi-color printing system supporting up to four filaments.
Automatic features of AD5X streamline the printing process.
The AD5X printer includes automatic bed leveling, a magnetic PEI build plate for easy part removal, and a quick-swap nozzle system. It also offers power loss resume functionality, which was crucial for long prints, and an intuitive touchscreen interface.
Slicer settings for PLA silk and support generation.
Recommended slicer settings include using PLA silk, setting wall generation to 'arachne', using three wall loops, 12% gyroid infill, and 'tree manual' supports. For large parts like the dome, slicing it in half or orienting it vertically is necessary for successful printing.
Optimal orientation and support painting for print quality.
Orienting parts like the main dome vertically minimizes the 'stairstepping' effect on curved surfaces, leading to a smoother finish. Support painting is used to precisely add supports only in necessary overhang areas (around 45°) and on the bottom lip of the faceplate for bed adhesion.
Slicing the face plate requires specific support strategies.
The face plate is printed at an angle to reduce VFAs. Supports are painted on the bottom half of the lip and inside threaded insert holes to ensure proper adhesion and a clean finish, as it only makes minimal contact with the build plate.
Coding the ESP32 Microcontroller
Configure Arduino IDE for ESP32-S3 Mini board.
The tutorial explains how to set up the Arduino IDE by installing the 'ESP32 servo' library and adding the ESP32 boards manager URL (github.com/espressif/arduino-esp32.git). It also guides on selecting the correct board ('ESP32S3 Dev Module') and COM port.
Adjust servo positions and speeds in the code.
Key code parameters include servo open/close degrees and open/close speeds. For example, servo close positions are set to 10° and 170° to account for opposite servo orientations. Speeds range from 1 (slowest) to 10 (fastest).
Control servo detachment to manage power and strain.
The 'detach servo at end' setting can be set to true or false. Setting it to false keeps servos powered, providing constant force to hold the faceplate open but potentially causing strain and faster battery drain. Default is 'true' for power saving.
Customize LED flicker effect and timing.
The LED eye logic allows customization of the flicker effect. Viewers can enable/disable the flicker, adjust the number of flickers, the interval between them (in milliseconds), and the delay after the faceplate closes before the flicker animation starts.
Upload the code to the ESP32-S3 Mini via USB.
After configuring the environment and code, the compiled sketch is uploaded to the ESP32-S3 Mini board through the selected COM port, using the USB-C connection.
Soldering and Circuit Board Assembly
Solder surface-mount components like USB-C with solder paste and heat gun.
For small surface-mount components like the USB-C connector, solder paste is applied to the board contacts, the component is placed, and then heated with a heat gun until the solder melts and cools.
Attach ESP32-S3 Mini to the PCB using pin headers.
Pin headers are soldered to the main circuit board, then the ESP32-S3 Mini is attached to these headers. Solder each pin, then trim the headers for a flush finish. Secure the ESP32 by soldering a few initial pins before finishing the rest.
Solder right-angle and JST connectors for servos and components.
Right-angle servo connectors and JST connectors are soldered onto the PCB. Pressure is applied to keep them flat while soldering each pin to ensure a strong and reliable connection.
Wire HUD LEDs, eyes, and reed switch to JST connectors.
The HUD LED lights, cosplay LED eyes, and magnetic reed switch are soldered to three-pin JST connectors. The middle pin connects to the data pin on the ESP32, and the left pin connects to ground. The red wire of the eyes goes to the data pin, and black to ground.
Prepare wires with heat shrink tubing for insulation.
Wires for components like the LED eyes are pre-soldered, heat shrink tubing is added over the joints, and then shrunk with a lighter for protection and a clean finish before connecting to the JST connector.
Modular JST connectors allow for future upgrades (e.g., RGB lights).
Three-pin JST connectors are used to provide modularity, allowing for future modifications such as using RGB lights or other components that might require data, positive, and negative pins within a single connector.
Helmet Assembly and Final Integration
Melt in brass threaded inserts for component mounting.
M3 brass threaded inserts are melted into the 3D printed helmet parts, primarily in the faceplate, to attach inner details and the motorization kit.
Follow Walsh 3D's PDF for detailed servo kit assembly.
The tutorial strongly recommends consulting the PDF guide provided by Walsh 3D for the Pro Motorization kit, which details assembly and includes a bill of materials.
Glue and weld major helmet components together.
3D printed parts such as eye details, lip, jaw, cheek details, and upper vent details are glued into place. The jaw and dome piece are further reinforced by welding them together with a soldering iron for maximum sturdiness.
Install magnetic reed switch and inner faceplate details.
Magnets for the back plate are glued in. M3 screws are used to attach the inner details to the faceplate.
Zero servo arms when servos are in the closed position.
Before final installation, power the servos to ensure they move in the correct open/close direction. Once confirmed, screw the servo arms into place when the faceplate is in the closed position to accurately zero their orientation.
Mount servo kit, faceplate, and route wiring.
The Pro Servo kit is screwed into the helmet, followed by the faceplate. Potential catching points might require sanding for smooth movement. Wires from the eyes are routed carefully to avoid snagging on the servo mount.
Install 3D printed circuit board mount and secure PCB.
A custom-designed circuit board mount is 3D printed and screwed into the helmet with M3 screws, ensuring the USB-C port faces away from the visor. Wires are tucked, and the PCB is screwed securely.
Glue the reed switch and complete the helmet assembly.
The magnetic reed switch is glued into place as the final electronic component. This step marks the completion of the motorized Iron Man helmet build.
Proper scaling is crucial for a comfortable fit.
The presenter notes that the helmet turned out slightly tight due to their larger head size, suggesting that printing a test ring for circumference or scaling the parts a few percent larger might be beneficial for a more comfortable fit.
Conclusion and Future Projects
Successful build utilizes silk filaments and Pro Motorization kit.
The presenter expresses satisfaction with the final appearance, noting the good look of the silk filaments and praising the design and functionality of the Walsh 3D Pro Motorization kit. The quality of the 3D models by Walsh 3D and VEC3D is also commended.
The developed PCB will be featured in future projects.
The presenter plans to include the designed helmet electronic circuit board in an upcoming Mark 6 helmet build, with added features, hinting at future content for viewers to anticipate.
Acknowledgements and call for comments.
Thanks are given to PCB Way for sponsoring the video and channel, and to Flash Forge for providing the AD5X printer. Viewers are encouraged to ask any questions in the comments section.
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Project Scope and Compatibility
This video focuses on building a motorized Iron Man helmet, specifically the Mark 45 model.
The tutorial details the process of creating a 3D printed motorized Iron Man helmet, covering scaling, printing, assembly, and electronics.
The primary kit used is the Walsh 3D 'Iron Man Servo Pro' all-in-one kit.
This kit is highlighted for its integrated motorization system that eliminates the need for external support arms and allows for easy scaling of the helmet.
The video does not mention or reference a 'Crash Works 3D ALISHA board'.
There is no information provided in the transcript about the compatibility or even the existence of a 'Crash Works 3D ALISHA board' in relation to this project.
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HOW TO MAKE a Motorized Iron Man helmet! - Mark 45 Tutorial and Flashforge AD5X showcase! - YouTube
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