This project began in 2021, shortly after Boba Fett’s on-screen revival in The Mandalorian (Season 2). It spanned three years while I worked through perfecting the sculpt and paint applications.

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The helmet was 3D modeled in Autodesk Fusion 360, along with a 3D printable matrix mold shell. The range finder was designed to house a custom tilt switch-activated LED circuit behind a magnetically held lens. After 3D printing the masters in SLA resin, the main helmet piece received a texture coat of thinned body filler to match the screen used prop before being molded in silicone and cast in urethane resin.

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I produced both finished versions: “Post Sarlacc” and “Re-Armored”. The Post Sarlacc paint job used a bright chrome base, masked off with liquid latex to achieve authentic paint chipping before custom mixed acrylics were applied. The Re-Armored helmet was a simpler process, using silver applied by hand to simulate minimal damage and machine cut vinyl stencils for the ear cap decals.

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Both versions received detailed weathering, a visor secured with chicago screws, working range finder electronics, and fabric interior liners. The only part of this project that was outsourced was the aluminum range finder stalk, produced by JJ Industries.