Shawn Thorsson’s Flametrooper helmet replica pays homage to the upcoming Force Awakens instalment of Star Wars

Shawn Thorsson’s Flametrooper helmet replica pays homage to the upcoming Force Awakens installment of Star Wars

Since Stormtroopers are always getting a bad rap because of their shooting skills, it only made sense that the First Order (formerly known as the Empire) outfitted some of their specialist Snowtroopers with a flame thrower — how can they possibly miss a target using a flame thrower? Then again, if you look at Shawn Thorsson’s Flametrooper replica helmet, the very thin slit for viewing nothing except what’s directly in front of the wearer might aiming hard.

 

Shawn hit up his friends over at DO3D.com to help him create a 3D model of the helmet

Shawn hit up his friends over at DO3D.com to help him create a 3D model of the helmet

Shawn began his stunning replica by getting in touch with his friends over at DO3D.com to help him produce a 3D model of the helmet using NetFab studio. Using the CAD model, Shawn then tapped a CNC machine to mill-out individual pieces of the helmet mold. He then glued the pieces together, primed them, and then filled in the seams and sanded it smooth. He then added layers of silicone, resin and fiberglass in an effort to prolong the mold’s lifespan.

 

Final mold assembly along with the first helmet prototype

Final mold assembly along with the first helmet prototype

After giving the prototype a quick, preliminary paint job, Shawn then set about creating the aerators for the front of the helmet, which were fabricated using a lathe to turn down a cast aluminum rod. Once glued into place, the helmet was nearing completion. After affixing some grey-tinted acrylic strips to the eye slit and a final ‘auto-quality’ paint job, the helmet was complete.

 

Things to come? It would seem Shawn is prototyping another Stormtrooper helmet, which may get a chrome-colored look. Captain Phasma perhaps?

Things to come? It would seem Shawn is prototyping another Stormtrooper helmet, which may get a chrome-colored look. Captain Phasma perhaps?

Of course, once you’ve made your own replica of one helmet, you probably will want to make others, which is what Shawn alluded to when he uploaded a photo of another prototype in the works. He alluded to a chrome color for the helmet as well, so does this mean Captain Phasma’s chrome-dome is in the works?

Can we get some paintball helmets and masks that are this cool already? Anyone?