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How we did it Cosplay custom made LED helmet with horns

How we did it: Cosplay custom made LED helmet with horns by ETERESHOP

Another adult cosplay custom LED helmet has extended our range of exclusive light up helmets. Let’s see how we have made it. 

Contents

Receiving an order for a custom LED helmet Mean Morris

On this stage, we clarify all the requirements from the customer.

Cosplay custom made LED helmet
Cosplay custom made LED helmet - reference picture from the customer
Idea for an adult cosplay custom LED helmet
Idea for an adult cosplay custom LED helmet
Reference picture for a cosplay custom made LED helmet
Reference picture for a cosplay custom made LED helmet

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.

3D sketch of a cosplay custom made LED helmet – front view
3D sketch of a cosplay custom made LED helmet – front view
3D sketch of an adult cosplay custom LED helmet – side view
3D sketch of an adult cosplay custom LED helmet – side view

The process of production

Making the spherical base of the helmet

As the base for the helmet we took a round plastic lamp.

Round plastic lamp for the LED helmet base
Round plastic lamp for the LED helmet base

We cut the bottom part of it to get a 23mm hole.

The bottom part of the lamp
The bottom part of the lamp
LED helmet plastic sphere with a 23mm hole
LED helmet plastic sphere with a 23mm hole

LED sphere design

The LED sphere was designed to fit the inner dimensions of the plastic sphere and hold the LEDs.

LED sphere design
Sketch of the LED sphere design

The ribs of the LED sphere were 3D printed from flexible plastic to be able to insert them inside the plastic sphere.

3D printed ribs for the LED sphere
3D printed ribs for the LED sphere

After all the ribs were assembled, we could solder the LEDs.

Soldering LEDs and fixing them on the inner sphere
Soldering LEDs and fixing them on the inner sphere
Inner LED sphere for a custom made light up helmet
Inner LED sphere for a custom made light up helmet
Covering the sharp edge of plastic sphere with a jacket
Inserting the LED sphere into the plastic one

Creating PET frame for LED helmet

In order to hold the LED sphere at the center of the lamp, we made additional frame from 2mm PET sheet.

PET frame design for holding the LED sphere at the right position
Sketch of the PET frame design for holding the LED sphere at the right position
Design sketch for fixing the helmet
Design sketch for fixing the helmet

The PET frame was fastened to the 3D-printed sphere with a help of tie-rods.

PET frame for holding LED sphere at the center of the round plastic sphere
Sketch of the PET frame for holding LED sphere at the center of the round plastic sphere
3D printed part
3D printed part for assembling the PET frame

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
Sketch of the head fixture for cosplay custom made LED helmet
Head fixture - side view
Sketch of the head fixture - side view

Head fixture for cosplay custom made LED helmet.

Inner hat from white EVA material
Inner hat from white EVA material
Element of head fixture
Element of head fixture
Head fixture for adult cosplay custom LED helmet
Head fixture for adult cosplay custom 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.

Fastening the PET fixture to the LED frame
Inserting the head fixture inside the plastic sphere
Inserting the head fixture inside the plastic sphere

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.

3D-printed eye for adult cosplay LED helmet, made of two glued elements
3D-printed eye for adult cosplay LED helmet, made of two glued elements
The eye after polishing
The eye after polishing
Glazed face elements
Glazed face elements
Painted face elements for Mean Morris LED helmet
Painted face elements for Mean Morris LED helmet
Before attaching the eyes we make the holes
Before attaching the eyes we make the holes
The face elements are attached with a help of two-sided tape
The face elements are attached with a help of two-sided tape

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.

Controller with SD card
Controller with SD card and a button to switch lighting effects manually
Boxes for batteries that connect to the controller
Boxes for batteries that connect to the controller
Controller for remote control of effects
Controller for remote control of effects

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.

Custom made LED helmet
Custom made LED helmet

If you liked the idea, see other posts by ETEREshop about how to make a LED and mirror outfits.

We will be pleased if you appreciate our work and share the article with your friends.

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