Engineer and 501st member Luke Daley is a powerful Jedi 3D designer. Inspired by Kylo Ren from Star Wars: The Force Awakens, Daley decided to design and print a replica helmet of the movie’s mysterious antagonist.
After seeing photos of the full Kylo Ren costume unveiled during this year’s Star Wars Celebration in Anaheim, Daley gathered every bit of reference material he could and spent nearly 100 hours designing in Solidworks to get every detail just right. He then went through four physical prototypes before settling on just the right shape and size. After the design and prototypes were completed, he printed, molded, sanded and painted the helmet himself—and I’d say it looks movie ready.
From concept to cosplay, check out photos from this grueling Kylo Ren 3D helmet process after the break.
Plans for the helmet can be downloaded at My Mini Factory
(via 3D Print)