Articulated Predator Halloween Mask

Predator mask with articulated jaw and mandibles.

This has been a challenge and a great learning opportunity for me. I wanted to make a mask for halloween that would be unique. Combining artistic creativity with mech design was a challenge for my go-to 3D software (OnShape). I opted for Fusion 360s sculpt/model ability but it was a new tool for me to learn.

So 3 weeks to learn Fusion360, design, prototype, print and publish. Oh and yes, there was the day job too :)
I can do a video of how i went about making this if there is interest.

Once 3D designed in place, each and every piece has been oriented by hand in a way that offers the best combination of strength, overhang-elimination, resolution and base-adhesion (there is one exception - see more below). The orientation in Thingiview is the target orientation on your print bed.
I will still be refining a couple of things (see below future enhancements), but at this point it's print ready. Apart from the prints you'd need a couple of rubber bands and something for the dreadlocks - and that's it.

Parts needed.

1. Check upper head dimensions for a fit on your head - scale if needed
   Print 1x Head Left, 1x Head Right, 1x Head alignment markers, 1x tab1, 1x tab2 and 1 or 2 x tab 3
   Support: Print with support touching the baseplate. Support needed for overhangs 30degrees or less (if 0 is horizontal).
   Orientation: Provides the best resolution for texture details on top of the head

2. Moveable jaw (again check dimension for a fit on your face first - scale if needed). Same scale to be used for parts in #3 below.
   Print 1x Jaw brace
   Support: None required

3. Moving Mandibles
   Print 1x Left mandible(jowl), 1x Right mandible(jowl), 2x Cam holder, 2x Cam, 2x Cam straps and 2x Hinge
   Support: For both the left and right mandible the orientation is the best for surface resolution and part strength BUT at the cost of base adhesion. So ensure heated bed. Supports needed for mandibles but not for others.

That's all the printing.

Assembly and use.

1. Join the two pieces of the head using the tabs (use as many as necessary don't have to use all 4) for alignment. Seal in place with ABS glue or superglue. Let cure.
2. Prime all parts (filler optional - as you might want to retain the organic texture).
3. Colour all parts.
4. Use 3 cut rubber bands to tie together the lower jaw pieces - see picture for guide. The other ends of rubber bands join the corresponding places on the other side.
5. Use another cut rubber band/elastic for the upper head piece to go around the back of your head. You can use styrofoam cut outs to brace back of mask against face / head.
6. The cam straps need to go around the back of your neck - print my extensible straps http://www.thingiverse.com/thing:1812743 (as many required) to do so.
7. Thread dreadlocks through the holes on the sides of the head. and some through the gaps. I'm using 10mm "backer rods" for dreadlocks - there is an useful video on youtube.

That's it. You might want black cream paint to colour exposed parts of your face to blend in and coloured contact lenses for eyes.
The mandibles open when you jut your head forward and the lower teeth / jaw move along with yours.

Future enhancements: I'll redesign the mandible retraction mechanism for more displacement. However I don't want you (or me :)) to reprint the major pieces so it'll work with the existing mandibles, jaw brace and head. The hinges / cam might need to be reprinted.

Credits: The design is based on and inspired by the Predator head 3D scan by MGD films (see image) https://sketchfab.com/models/d8173f7c20bb44fda109544c8e5000a6