Boba Fett Helmet

One of my favorite projects! I designed a model of Boba Fett's helmet, taking care to include every detail including the dent. The helmet was first test cut out of machinable wax, then machined out of aluminum on the Haas Mini Mill. I used a fixture and three cutting orientations. Due to the limited time I had on the machine, I wasn't able to use as fine of a step down as I would have like to, and spent about 45 hours sanding and polishing it to get the finish that I wanted. It ended up being so shiny that I couldn't take a picture of it without getting the reflection of the camera in it. I then had the part anodized clear to prevent it from damage. 

Next Project