Another adult cosplay custom LED helmet has extended our range of exclusive light up helmets. Let’s see how we have made it.
Receiving an order for a custom cosplay helmet Mean Morris with Leds
On this stage, we clarify all the requirements from the customer.
Our client’s main wish was to get a very much alike helmet with the pictures above. The LED sphere should be hidden inside the plastic sphere.
Creating a 3D sketch
3D sketching not only helps to visualize the future design and present it to the customer, but also make precise drawings for further production.
The process of production
Making the spherical base of the cosplay helmet
As the base for the helmet we took a round plastic lamp.
We cut the bottom part of it to get a 23mm hole.
LED sphere design
The LED sphere was designed to fit the inner dimensions of the plastic sphere and hold the LEDs.
The ribs of the LED sphere were 3D printed from flexible plastic to be able to insert them inside the plastic sphere.
After all the ribs were assembled, we could solder the LEDs.
Creating PET frame for LED cosplay helmet
In order to hold the LED sphere at the center of the lamp, we made additional frame from 2mm PET sheet.
The PET frame was fastened to the 3D-printed sphere with a help of tie-rods.
Сreating a retainer for the head
To make the helmet convenient to wear, we designed special head fixture.
Head fixture for cosplay custom made LED helmet.
The hat is fastened to the PET fixture with a help of tie-rods and the fixture to the LED frame with bolts and nuts.
Designing the face elements
All of the face elements were 3D-printed – eyes, eyebrows, a nose, horns, a mouth and a pipe. Those consisting of several parts were glued, polished and glazed, and then covered with paint.
Effects and connections
Our aim was to create highly dynamic and bright effects. Most of the effects are multicolor and have their own unique patterns and shape.
We draw the effects in the “Madrix” program. This program has all the necessary functionality to create lighting effects. We record effects using our company’s software – ETERESHOP effects recorder. Thanks to the recorder, the effects created in the Madrix are recorded in text files with the names “S№”, the effect numbers are also determined in the recorder. These text files are downloaded to the SD card, which is inserted into the controller. Well, the controller reads these files and converts the effects to the product. There are quite a lot of different templates and settings for them in the “Madrix” itself, so they can be changed – this is how effects are created.
Look at what helmet we got
The custom-made helmet has 1807 LEDs and runs on batteries for about 2 hours. It is clearly visible in it and it does not restrict movement, which allows you to play at the DJ console and dance in it.
We will be pleased if you appreciate our work and share the article with your friends.
Check out other LED cosplay helmets by ETERESHOP