This is Col. MAEL RADEC from the video game Killzone. This was made for a film. This Radec armor represents my first attempt at building armor using EVA foam.
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Here's how this helmet was created:
Foam male armature mounted on bead foam with supports. WED CLAY
After the first session or 2 of sculpting (WED clay) I like to take a still, examine it against reference photos, and make notes for the next few scultping sessions.
Once the shape is primarily blocked out, it helps to have corresponding shapes as reference during the sculpt, to help make allignments, etc. Here are the vector files I created to laser cut these reference parts.
The resulting laser-cut components:
Shaping and final blocking begin on the sculpt.
In this example, styrene 'pans' are created and inserted into the sclupt to create the necessary design features. Then final smoothing and the waste mold begins.
There is so only so far you can take a clay sculpture as far as 'smoothing'. To get hard endged, hard-cornered, machined metal smoothness, you need to work from a resin casting. To create this initial casting a 'waste mold' needs to be created. Here's the first stage of this step:
Completed mold (waste mold version 1):
Once a postive cast was made, we created a positive plaster buck of the TOP of the helmet to be able to create a thermal formed shell that could be detailed properly, and then reattached to the helmet.
What you see being detailed and smoothed here is the FIRST GENERATION casting. Once this was cleaned up and smoothed, it became the HERO PATTERN which is then molded AGAIN to create the master mold. This represents the OLD school method of building helmets. I recently bought a 3D printer so this may be the one of the last helmets I build in this fashion... we'll see.
Here you see some laser cut detail parts, and some foam that is carved into the needed shapes.
Here's the MASTER PATTERN being molded.
And the resulting casting (2nd generation)...
AND NOW THE BODY ARMOR:
Sculpting team Cris A. Chuck W.
EVA FOAM MASTER: BRANDON B.
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