1:6 Darth Vader 3D Laser Scan & Print Project

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And this is how they look in the teeth and chin vent.

v2 - Project - 170 - 2024-06-12.png

v2 - Project - 171 - 2024-06-12.png
 
Anyone know if there are D-rings publicly available that is in size with a 1:6 scale lightsaber, or does it have to be custom made?

Thickness - 0.5mm
Hight - 3.904mm
Width - 5.364mm

v2-Project-167.jpg
 
In case anyone's interested in seeing what I need to do to clean up the geometry.

The teeth gaps that still looks messy (to the left) has the whole inner edge separated, so it registers as unconnected. The issue comes from when I cut out that grill box shape on the inside of the face mask. I had missed a setting, so it didn't fuse the cut into the model, but kept the new shape as a separate piece.

Thankfully the other facemask's didn't have this issue.

And since I have to mess with every single polygon anyway... there's no reason not to simplify and clean things up. It will also remove size on the file. I couldn't use optimize or automatic tools, as that screwed up the shapes, so I'm doing things manually, fixing one polygon at a time. Which is fairly time-consuming.

v2 - Project - 173 - 2024-06-28.png
 
Finally managed to get some energy to add the dome rings inside the ESB and RotJ domes that connects with the dome ring on top of the face masks. Uncertain whether the tolerance is good - we will see once we get some sets printed. I gave the ring and screw cutouts enough space, hopefully, for them to sit right every time, so they can just be glued down once the parts are painted.

Now I just need to fix some topology errors along the perimeter of the inside of the domes... that may take a few days' worth of work... and then I will have to figure out whether I will add a spacer inside the ANH dome so it will sit correct every time or whether I should just let people sort that, so they can match a specific dome position look from the movie themselves, which wouldn't be possible if I locked things down. The dome in that movie - due to the 3 apple tabs dome system - was all over the place. No wonder they changed it to the ring mounts, as people working on the movie and tour has stated that it was a complete PITA to put the dome on right and securely.
 
Was pointed out by Mike Warren that I might have made the RotJ dome widows peak too straight, so I had help from a good friend to fix it and here's the result.

The change is minor, but the effect is major. Though I have seen RotJ helmets with the more square look... but it might have been fanmade ones or a trick of the light in medium res pictures. Uncertain.

Regardless... this is much better now. So thanks guys.

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Great work!

If I might suggest another possible improvement: the teeth cutouts are a bit too rounded on the ESB and ROTJ at the moment IMO. It's making the empty slots in between look more like ovals than rectangles, particularly the third and fourth from the left.

Here's a reference compilation I made for the teeth (and chin vent) when I sculpted mine, that hopefully shows what I mean.
Mouth & chin vent reference_3.png
 
Since we will print them hollow and without grills as part of the print, people who wants to fix this can do so with fine jewellers files from the inside. I know it is possible to get in there physically to file those corners straight, as I did it on the original v1 master castings we were going to mold and cast, but because the teeth are so thin in that scale, people need to be really careful not to break them when working in there.

Also, those masters were cast resin. Uncertain if 3D printed resin is as strong as that. So be extra careful.
 
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