My Ironman helmet was built 80% by hand and 20% with digital fabrication. I had to experiment with different materials. I used servomotors, LEDs, and electronics. The process basically consisted in making the 2D development from a 3D model of the helmet using Pepakura software. Once I got the 2D development I could print it using a traditional 2D paper printer.
He then traced those paper pieces onto the foam before fitting it together like a puzzle and adding the finishing touches to the outside to make it look just like Iron Man’s helmet.
See video of the helmet in action after the break…