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Fullmetal Alchemist Alphonse's Helmet

Fullmetal Alchemist Alphonse's Helmet cosplay

Recently I purchased a new piece of software called Armorsmith. It's a program that allows you to create an avatar of yourself with adjustable dimensions, then import 3D models and Pepakura files to scale to fit your body. You can then create paper patterns from that or export them for 3D printing.

I was looking for a quick project to gain skills with this program, so I went for Alphonse's helmet from Fullmetal Alchemist - his real one this time. I started by modifying a model from Thingiverse (by user richdog567). This was done in Blender by using "limited dissolve" to simplify the geometry, then removing any edges that would be created via foam thickness.

From this model, I imported it into Armorsmith, scaled it and started to generate the patterns. Once done I could print one half out and begin assembling it onto foam.

The patterns still required adjustment, due to foam being different to paper and more details needing to be added. Once the bulk of the construction was done, I added the trim and rivets, some wild battle damage (this is an end of FMA version of his helmet) then cleaned up seams. Sealing was done using Flexbond and a bit of water.
Fullmetal Alchemist Alphonse's Helmet cosplay

Fullmetal Alchemist Alphonse's Helmet cosplay

Fullmetal Alchemist Alphonse's Helmet cosplay

Once sealed, I primed with flat black spray paint and then roughly (but evenly) went over with a layer of aluminum spray paint. I wanted to add shading in the corners but alas my airbrush still wasn't working, so I hand painted them in, watering down metallic and black paint, dabbing it on and blotting it off again. When dry I glued in black fabric behind the eyes and the helmet was done!

Fullmetal Alchemist Alphonse's Helmet cosplay

Fullmetal Alchemist Alphonse's Helmet cosplay

Fullmetal Alchemist Alphonse's Helmet cosplay


I decided to take this picture (pre-painting) to celebrate Easter. A little homage to the manga series.

Fullmetal Alchemist Alphonse's Helmet cosplay



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