After writing the scriptment for this short I was keen to begin work on the costumes, I knew that these would take some time to put together so i modelled the helmets from scratch in Maya and exported them to a software package called Pepakura designer. This program allowed me to uv the helmet and then print it on card. The plan was to then fibreglass and resin the card stock and then build up the details and smoothness with bondo, (a polyester putty.) In the end I ended up redesigning the helmet a few times. The first image is the first design followed by the final design and the design in Pepakura.
As you can see in Pepakura the sections of the model are cut and flattened across several A4 sheets, each section is printed with tabs and edge identifiers to help attach them.
As with all prop building there are many other methods out there. If I had all the required equipment and time I would have preferred to try sculpting the helmets in clay and using that to create a cast. Doing it that way would have meant several helmets could be cast identically and quickly while the Pepakura route means each helmet has to be hand made.
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