This project was one of my largest undertakings so far. The goal was to replicate Boba Fett's helmet from The Book of Boba Fett with the highest fidelity to the original screen-used helmet, inside and out.

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The helmet was 3D modeled in Autodesk Fusion 360 with the utmost attention to detail. Two versions were prepared; one intended for an open slush cast mold and another for a cored mold that would capture the interior details as well. The interior of the cored helmet included additional details that are an approximation of the screen-used helmet. A range finder topper was also designed to house a custom LED circuit, with tilt activation and a magnetic lid to conceal the circuit.

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Both versions of the helmet followed similar production workflows. They were cast in a urethane resin and painted with a layering of automotive and acrylic paints to achieve the screen-accurate appearance. The final surface finish is textured, with polished high spots to give it the unique and unmistakable light sheen of the Book of Boba Fett helmet. The ear caps were detailed with cut vinyl stencils.

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Both helmets received removable visors and interior fabric liners. A “Daimyo” cold-cast coin and painted resin stand were also designed to accompany the cored helmets.

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The cored mold making was outsourced to a mold shop, and the aluminum stalk, cheek greeblie, and upper right ear assembly were provided by JJ Industries and MachineCraft Replicas. All other work was completed in-house.