Here we place our collective tools, tips and processes for the gathering, processing and producing of replica props using the 3d print in combination with other casting and finishing tools. For years, I have hand built some things, sculpted others in clay and created molds and used multiple materials as final casts in the creation of at least portions of replica props. In my pursuit of screen accurate cosplay, I have found that many of the smaller items in a costume are simply not available as an aftermarket purchase and not popular enough in themselves to be already available as a collectible. This void of availability has led me to wish I could more easily produce these one off items and allow others to benefit from that effort without needing to become master sculptors or wait for a production run. After leaning hard into the learning curve for 3d scanners, digital design software, 3d printing and post print finishing and weathering, I realize that even these steps were worth sharing rather than just the single cosplay or item I was focused on for the present. I am going to be posting here, the links, the videos, the samples, settings and tips that I have gathered in this short time in this new world. Many of you if not most have more experience in this than I and some of these "tips" will seem silly or newb and they will be because that is where I am. Newb struggling with these awesome tools, one step below Star Trek Replicator.
For my first post I want to share a process that was as close to natural as I could get with the added ability of sharing the result across the internet with therpf members who were working on the same prop, at the same time.
I sculpted my prop using a non drying clay, real world sculpting. Something that wasn't going to push me over the edge for unfamiliar tech on day one. Once I had my starting point, I borrowed a 3d scanner from my aunt and struggled through learning how to use it "new out of the box". This led to learning "mesh" software which is NOT a design software in the historical sense but made especially for taking measured scans of a 3d object and mapping it into a shape using hundreds of separate points (just like the dots they throw on a motion capture actor). This is then opened into a true 3d software program (some are both mesh and 3d in one). At this stage the design can be shared and sent electronically to collaborate with other uber prop fans around the world, which we did. When the file was complete and it was time to go to printing, it has to go through another piece of software called a slicer that cuts it into the layers it needs to be printed on a 3d printer (there are many many kinds) or to be fabricated using a cnc mill or similar. These two processes are creating the same object but one is adding material and the other taking it away. The file was the same originally but one went to create code for a milling machine, lathe or router while the other code was for printing. Printers can print in many ways and in many materials. Once the prop was printed it needed to be prepped for paint which included different types of sanding, filling and surfacing. After all of this, it is finally ready for paint and weathering/aging.
One of the COOLEST aspects of this crazy digitization of prop making is that once it is living in the digital world, as a finished 3d object, it can be scaled up or down easily during the printing or machining processes. It can even be used as an object in games, in photos and in videos. Imagine being the super fan that happens to be a foot and a half taller than the actor from the movie. The prop can be scaled up to match your size and your finished photos can look very similar to the original instead of "Big maaaaan in a little cooooaaaat...." (and yes, I miss Chris Farley).
So here I will post all of the links and tips I have picked up from other threads and from all the rpf'ers who insist on being cool and lending a hand to newbs, which is most of them. Please post at will and on whichever portion of the process you wish to talk about. I certainly will not be maintaining the thread nor refereeing content. It is just a spot to post your tips and your questions and hopefully your success and failure pictures as well. If you have a thread of this nature or of a specific portion of this, Please Please Please, add a link here so everyone can find you and your info. Many of my links will be external videos or software so always be cautious and safe about how you surf, follow, or download as nothing on the internet is without its risk and what might be a working link one day can be hijacked the next.
And always expect that I am resharing and am not a pro saying my way is the only way. Call me out on anything you see that is just simply wrong or offer a better way.
Here is a link I found today that actually resolved at least 10 if not maybe all 12 of the common newb issues in the 3d software called Blender:
For my first post I want to share a process that was as close to natural as I could get with the added ability of sharing the result across the internet with therpf members who were working on the same prop, at the same time.
I sculpted my prop using a non drying clay, real world sculpting. Something that wasn't going to push me over the edge for unfamiliar tech on day one. Once I had my starting point, I borrowed a 3d scanner from my aunt and struggled through learning how to use it "new out of the box". This led to learning "mesh" software which is NOT a design software in the historical sense but made especially for taking measured scans of a 3d object and mapping it into a shape using hundreds of separate points (just like the dots they throw on a motion capture actor). This is then opened into a true 3d software program (some are both mesh and 3d in one). At this stage the design can be shared and sent electronically to collaborate with other uber prop fans around the world, which we did. When the file was complete and it was time to go to printing, it has to go through another piece of software called a slicer that cuts it into the layers it needs to be printed on a 3d printer (there are many many kinds) or to be fabricated using a cnc mill or similar. These two processes are creating the same object but one is adding material and the other taking it away. The file was the same originally but one went to create code for a milling machine, lathe or router while the other code was for printing. Printers can print in many ways and in many materials. Once the prop was printed it needed to be prepped for paint which included different types of sanding, filling and surfacing. After all of this, it is finally ready for paint and weathering/aging.
One of the COOLEST aspects of this crazy digitization of prop making is that once it is living in the digital world, as a finished 3d object, it can be scaled up or down easily during the printing or machining processes. It can even be used as an object in games, in photos and in videos. Imagine being the super fan that happens to be a foot and a half taller than the actor from the movie. The prop can be scaled up to match your size and your finished photos can look very similar to the original instead of "Big maaaaan in a little cooooaaaat...." (and yes, I miss Chris Farley).
So here I will post all of the links and tips I have picked up from other threads and from all the rpf'ers who insist on being cool and lending a hand to newbs, which is most of them. Please post at will and on whichever portion of the process you wish to talk about. I certainly will not be maintaining the thread nor refereeing content. It is just a spot to post your tips and your questions and hopefully your success and failure pictures as well. If you have a thread of this nature or of a specific portion of this, Please Please Please, add a link here so everyone can find you and your info. Many of my links will be external videos or software so always be cautious and safe about how you surf, follow, or download as nothing on the internet is without its risk and what might be a working link one day can be hijacked the next.
And always expect that I am resharing and am not a pro saying my way is the only way. Call me out on anything you see that is just simply wrong or offer a better way.
Here is a link I found today that actually resolved at least 10 if not maybe all 12 of the common newb issues in the 3d software called Blender:
