See The Hands-on Details Behind Stunning Helmet Build

[Zibartas] recently created wearable helmets from the game Starfield that look fantastic, and we’re happy to see that he created a video showcasing the whole process of design, manufacture, and assembly. The video really highlights just how much good old-fashioned manual work like sanding goes into getting good results, even in an era where fancy modern equipment like 3D printing is available to just about anyone.

The secret to perfectly-tinted and glassy-smooth clear visors? Lots and lots of sanding and polishing.

The visor, for example, is one such example. The usual approach to making a custom helmet visor (like for Daft Punk helmet builds) is some kind of thermoforming. However, the Starfield helmet visors were poor candidates due to their shape and color. [Zibartas]’s solution was to 3D print the whole visor in custom-tinted resin, followed by lots and lots of sanding and polishing to obtain a clear and glassy-smooth end product.

A lot of patient sanding ended up being necessary for other reasons as well. Each helmet has a staggering number of individual parts, most of which are 3D printed with resin, and these parts didn’t always fit together perfectly well.

[Zibartas] also ended up spending a lot of time troubleshooting an issue that many of us might have had an easier time recognizing and addressing. The helmet cleverly integrates a faux-neon style RGB LED strip for internal lighting, but the LED strip would glitch out when the ventilation fan was turned on. The solution after a lot of troubleshooting ended up being simple decoupling capacitors, helping to isolate the microcontrollers built into the LED strip from the inductive load of the motors.

What [Zibartas] may have lacked in the finer points of electronics, he certainly makes up for in practical experience when it comes to wearable pieces like these. The helmets look solid but are in fact full of open spaces and hollow, porous surfaces. This makes them more challenging to design and assemble, but it pays off in spades when worn. The helmets not only look great, but allow a huge amount of airflow. This along with the fans makes them comfortable to wear as well as prevents the face shield from misting up from the wearer’s breathing. It’s a real work of art, so check out the build video, embedded just below.

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Star Wars-Inspired Cosplay Prop Uses Old Vintage Camera

Lots of people make replica lightsabers from Star Wars or tricorders from Star Trek. Not so many people have tried to recreate the binoculars from The Last Jedi, but [The Smugglers Room] whipped up a pretty rad pair from old parts.

It’s more of an inspired build rather than screen-accurate, but they’re still pretty neat. A Bell & Howell camera was the basis for the binoculars used in the film, in fact, and this build starts with the same tri-lens model. Found vintage objects are often used in sci-fi with some modifications, but more commonly in lower-budget productions. Star Wars can do it too, though, it seems.

Turning them into binoculars requires the construction of a viewfinder, which was made out of hand-cut Sintra PVC foam board. Lots of leather wrap had to be removed from the camera, too, which offered a happy accident—it left a heavily-weathered aluminum surface that looked great for a Star Wars prop. A few random controls were then added to disguise the camera as an advanced pair of futuristic binoculars. LED lighting was also installed internally to make the build glow as if it actually contained some powered sci-fi optics. It also got a hand-made leather strap for that rugged aesthetic so fitting for the film.

It’s not a functional build; we’d love to see someone build a set of AR or rangefinder binoculars that still look the part. However, this would be a great addition to any Poe Dameron costume you might have planned for the next upcoming Comic Con.

Here’s our question, though. Does it suck you out of your suspension of disbelief when filmmakers use found objects as the basis for props? Or is it a neat thing when you spot such an example? Video after the break.

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Building Penny’s Computer Watch From Inspector Gadget

When you help your bumbling Uncle Gadget with all kinds of missions, you definitely need a watch that can do it all. Penny’s video watch from Inspector Gadget has a ton of features including video communication with Brain and Chief Quimby, a laser, a magnet, a flashlight, a sonar signal, and much more.

To round out her Penny costume, [Becky Stern] has created a 3D printed version of Penny’s incredibly smart watch. It listens for Penny’s iconic phrase — come in, Brain! — and then loads a new picture of Brain on the rounded rectangle TFT display. Inside the watch is an Arduino Nicla Voice, which has to be one of the tinier machine learning-capable boards out there.

[Becky] created the watch case in Tinkercad and modified a watch band from Printables to fit her wrist. With such a small enclosure to work with, [Becky] ended up using that really flexible 30 AWG silicone-jacketed wire for all the fiddly connections between the Arduino and the screen.

After getting it all wired up to test, she found that the screen was broken, either from pressing it into the enclosure, or having a too-close encounter with a helping hands. Let that be a lesson to you, and check out the build video after the break.

More interested in Uncle Gadget’s goodies? Check out these go-go-Gadget shoes and this propeller backpack for skiers.

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Supercon 2022: [Liz McFarland] Builds Golden Wings, Shows You How

Are you, by any chance, wondering about giving yourself wings? You should listen to [Liz McFarland] sharing her experience building a Wonder Woman suit, and not just any – the Golden Eagle suit from Wonder Woman 1984, adorned with a giant pair of wings. If a suit like that is in your plans, you’ll be warmly welcomed at a cosplay convention – and [Liz] had her sights on the San Diego Comic Con. With an ambitious goal of participating in the Comic Con’s cosplay contest, the suit had to be impressive – and impressive, it indeed was, not just for its looks, but for its mechanics too.

[Liz] tells us everything – from producing the wings and painting them, to keeping them attached to the body while distributing the weight, and of course, things like on-venue nuances and safety with regards to other participants. The dark side of cosplay building reality isn’t hidden either – talking, of course, about the art of staying within a reasonably tight budget. This build takes advantage of a hackerspace that [Liz] is an active member in – the [Crash Space] in LA. Everything is in – lasercutting, 3D printing, and even custom jigs for bending wing-structual PVC pipes play a role.

It would have been a travesty to not have the wings move at will, of course, and [Liz] had all the skills you could want for making the wings complete. She went for two linear actuators, walking us through the mechanical calculations and considerations required to have everything fit together. It’s not easy to build a set of wings on its own, let alone one that moves and doesn’t crumble as you use it – if you have already attempted bringing mechanical creations like this into life, you can see the value in what [Liz] shares with us, and if you haven’t yet delved into it, this video will help you avoid quite a few pitfalls while setting an example you can absolutely reach.

The suit was a resounding success at the con, and got [Liz] some well-earned awards – today, the suit’s story is here for the hackers’ world. Now, your cosplay aspirations have an inspiring real-life journey to borrow from, and we thank [Liz] for sharing it with us.

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3D printed Hagrid's lantern with a magic wand

Micro:bit Brings 3D Printed Magic Lanterns To Life

[Elenavercher] loves engaging her primary school students, inspiring their imagination as well as teaching them the design thinking process. She has found that the very accessible rapid prototyping culture of 3D printing, micro:bit, and the like are perfect for teaching her students problem-solving and teamwork, and is always coming up with new lessons that will catch their attention. That brings us to her latest design, an interactive lantern and wand, which you could say is of the wizarding variety.

The lantern and the wand each have an integrated micro:bit serving as their brains. When the user shakes the wand, releasing a spell, the micro:bit in the wand, sends a user-defined number to the micro:bit in the lantern. The lantern has NeoPixels built-in, which then turn on, illuminating the lantern. When the user presses a button on the micro:bit instead of shaking it, the wand sends a signal to the lantern that tells it to “turn off.” Pretty simple, right?

The design itself is something any seasoned hacker could recreate; however, the magic in this build is how [Elenavercher] beautifully engages her elementary-aged students in the engineering design process. She starts off by encouraging her students to prototype the lantern and wand using paper which is a very inexpensive way to help them visualize the final product before investing too much time into the 3D design, a critical engineering design step — prototype fast and cheap with whatever you have on hand.

She then helps them design the lantern and wand in Tinkercad, a very beginner-friendly, yet increasingly capable CAD program. We really appreciate her detailed steps for the design as well as for navigating Tinkercad, both of which will help teach any tiny tikes in your life how to recreate the design. What’s really handy about Tinkercad is you can do mechanical CAD as well as write code for the micro:bit all within the same program. But [Elenavercher] also provides the final .hex file if you’d rather just get the build up and running.

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A montage of a "death stranding" lamp in two different color modes, purple on the left and blue on the right

Illuminate Your Benched Things With This Death Stranding Lamp

[Pinkman] creates a smart RGB table lamp based off of the “Odradek device” robot arm from the video game “Death Stranding”.

[Pinkman] adds a XIAO BLE nRF52840 Sense device, with Bluetooth support, microphone and TinyML capability. The nRF52840 is used to push data to the five WS2812 strips, one for each “blade” of the lamp, and also connects to a TTP223 capacitive touch controller to add touch input detection. The TinyML portion of the nRF52840 allows for custom keyword training to turn on the lamp with voice commands ([Pinkman] uses “Bling Bling”). [Pinkman] has also provided Bluetooth control, allowing the color and pattern to be changed from a phone application.

The lamp is 3D printed with the build being based off of [Nils Kal]’s Printables files. Each of the five blades has a white 3D-printed diffusor plate to help ease out the hot spots for the LED strip. The lamp is fully adjustable in addition to having cavities, channels and access points for “invisible” wiring. [Pinkman] has also upgraded the original 3D files to allow for the three wires needed to drive the WS2812, instead of the two wires that [Nils] had allotted in the original.

[Pinkman] has all of the code, STL files and training data available for download, so be sure to check it out. Lamps are a favorite of ours and we’ve featured our fair share, including 3D printed Shoji lamps and RGB wall lamps.

Video after the break!

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Halloween Build: Exquisite Ray Gun Has Sound Effects

When we first saw [lonesoulsurfer’s] ray gun, we thought it looked oddly familiar. Sure, it looks like a vintage ray gun you might see in a dozen 1950-era movies or TV shows. But still, there was something oddly familiar about it. Turns out, the core piece of it is an old-fashioned timing light used when doing a car tune-up.

This is no unobtrusive Star Trek phaser. It looks substantial and has a cool sound generator that not only gives it something to do but also sports cool control knobs out the top of the gun. The design files for the sound circuit are in a Google drive folder if you want to recreate the build.

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