Keyshot Render
Keyshot Render

The helmet was designed to be two pieces: a solid aluminum front face, with a 3D printed rear portion to get the desired color scheme.

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SolidCAM Screenshot
SolidCAM Screenshot

This was my first experience with using SolidCAM to generate GCode. I gained a lot of valuable experience about how to achieve organic surfaces and geometry given a limited number of tools

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Sanding for Desired Finish
Sanding for Desired Finish

I sanded down the aluminum finish from as rough as 80 grit down to as smooth as 720 grit to get a smooth, scratch less surface

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Keyshot Render
Keyshot Render

The helmet was designed to be two pieces: a solid aluminum front face, with a 3D printed rear portion to get the desired color scheme.

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War Machine Helmet

As part of my Integrated CAD/CAM/CAE class (IPD 501), I was tasked with creating a piece of desk candy. I chose to design some Marvel superhero memorabilia, namely an aluminum replica of the character War Machine's helmet. I designed the helmet in SolidWorks, programmed GCode using SolidCAM, and finally milled the helmet using a Haas CNC Minimill.

In order to preserve the color scheme along the profile of the helmet, I decided to mill two separate parts, one for the metallic front profile and another for the black portion of the mask. When I mill the second part, I hope to achieve the color by anodizing it black.