Din Djarin's Helmet, The Mandalorian (S1)
Din Djarin's helmet from The Mandalorian (Season 1) holds special significance as my first proper helmet 3D model, marking the beginning of my interest in replica helmets in 2019.
Modeled entirely in Autodesk Fusion 360, the main helmet was printed in ABS filament and the detail parts were printed in SLA resin. The main helmet was molded in silicone using a brush-up approach, initially using a fiberglass outer shell before switching to an epoxy air clay shell. The detailed parts were molded using two-part molds, also going through a few iterations including 3D printed matrix mold shells.
The final pieces were then cast in urethane resin and painted with a chrome finish, using 2K automotive gloss clear and Imperial Surface Alumaluster. The Alumaluster was deliberately applied at a lower opacity to achieve the screen-accurate, slightly muted appearance. The helmet was completed with subtle oil paint weathering, a removable visor, and a fabric interior liner.
