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STL MK5 Build Manual
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STL MK5 Build Manual

Iron man helmet
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Iron Man Helmet
MK5
Build Guide

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Summary of Contents for STL MK5

  • Page 1 Iron Man Helmet Build Guide...
  • Page 2 Thank you! And Welcome! This build guide accompanies the STL files you’ve downloaded in order to build your own Iron Man MK5 helmet. Before starting the build you will need all the parts printed as well as all the wiring done with code uploaded to Arduino.
  • Page 3 Step 1. Step 2. Start with Dome04 and Dome03. Use two m2x4mm bolts to attach. Step 3. Step 4. Add Dome02. Use two m2x4mm bolts to attach in the back. Step 5. Step 6. Use two m2x4mm bolts to attach by the ears. Admire Dome04, Dome03, Dome02.
  • Page 4 Step 7. Step 8. Collect Jaw, Mouth, Chin. Use three m2x4mm bolts to attach Jaw and Mouth. Step 9. Step 10. Use three m2x4mm bolts to attach Chin and Mouth. Bring back in the domes. Step 11. Step 12. Use two m2x4mm bolts to attach by the ears. Use two m2x4mm bolts to attach by the left cheek.
  • Page 5 Step 13. Step 14. Use two m2x4mm bolts to attach by the right cheek. Admire again (the hard part starts now). Step 15. Step 16. Grab Dome01 and PCA9685 (wired up already). Use four m2x6mm bolts to attach PCA9685. Step 17. Step 18.
  • Page 6 Step 19. Plug the servo into PCA9685 #0. Connect Step 20. Rotate the servo into closed position (using Arduino, button and power. button) and attach the arm at this angle. Step 21. Step 22. Place servoArm_Main and use m2x8mm to attach. Grab arm_Main and insert m3x8mm as shown.
  • Page 7 Step 25. Step 26. Insert m3x10mm bolt. Place the washer. Step 27. Step 28. Find the brow_main. Attach as shown. Step 29. Switch the servo position to open (using the Step 30. button) and insert m3x10mm bolt. Add the washer.
  • Page 8 Step 31. Step 32. Bring brow_main into position and attach. Run a test and it show look like this closed. Step 33. Step 34. And like this open. Now repeat on the other side with new servo #1. Step 35. Step 36.
  • Page 9 Step 37. Step 38. Attach brow_center_mount with four m3x6mm bolts. Find servo #2 (proper wire length). Step 39. Step 40. Place it as shown. Attach with two m2x8mm bolts. Step 41. Step 42. Plug the servo into PCA9685 #2. In closed position (button), this is the arm position.
  • Page 10 Step 43. Step 44. Attach servoArm_B with screw that came with servo. Grab brow_side. Step 45. Insert m3x8mm bolts into arm_A and top it Step 46. with a washer. Attach to brow_side as shown. Step 47. Step 48. Insert m3x8mm bolt and washer into the arm. Attach to brow_main as shown.
  • Page 11 Step 49. Step 50. Insert m3x8mm bolt into servoArm_B with a washer. Attach to brow_side as shown. Step 51. Step 52. Test it out at closed. And at open. Step 53. Step 54. Repeat on the other side with servo #3. Movement must match across both sides.
  • Page 12 Step 55. Step 56. The rest of the face assembly will easier to Remove four bolts on the brow_center_mount. build separate. Step 57. Step 58. Find servo #4. Place as shown. Step 59. Step 60. Attach with two m2x8mm bolts. Trim some plastic for clearance.
  • Page 13 Step 61. Step 62. Plug servo in into PCA9685 #4. In the closed position, the arm must be as shown. Step 63. Step 64. Remove the servo at attach the servoArm_A. Install the servo back in. Step 65. Step 66. Prep arm_A with m3x8mm bolt and a washer.
  • Page 14 Step 67. Step 68. Attach arm_A to brow_center. And another arm_A on the other side. Step 69. Step 70. Place m3x8mm bolt and a washer into arm_A. Attach to brow_center_mount. Step 71. Step 72. And attach the other arm as well. Insert m3x8mm into brow_center.
  • Page 15 Step 73. Step 74. Screw that bolt into servo arm. When animated, brow_center should lay flat. Step 75. Step 76. And at open it should raise just so. Moving on, and grad servo #5. Step 77. Step 78. Place and attach with two m2x8mm bolts. At closed position, this is the servo arm position.
  • Page 16 Step 79. Step 80. Prep another arm_A with m3_8mm bolt and washer. Attach arm_A to brow_center_mount. Step 81. Step 82. Duplicate on mirror side. Attach servoArm_A to the servo. Step 83. Step 84. Prep open side of arm_A with m3x8m bolts Grab your nose_center.
  • Page 17 Step 85. Attach the bolts to nose_center through the Step 86. access hole. On both sides. Step 87. Step 88. Prep nose_center with m3x8mm bolts and washer. Screw the bolts into servo arm_A. Step 89. At close, nose_center must be flat and aligned Step 90.
  • Page 18 Step 91. Step 92. Find servo #6 Place and attach with m2x8mm bolts. Step 93. Step 94. Servo arm position at close. Attach servoArm_A. Step 95. Step 96. Prep arm_B with m3x8mm bolt and a washer. Attach to nose_center as shown.
  • Page 19 Step 97. Step 98. Grab nose_side Attach with m3x8mm bolt to arm_B. Step 99. Step 100. Prep nose_side with m3x8mm bolt and a washer Screw into servoArm_A (a bit tricky angle). Step 101. Step 102. When closed, the parts should line up and be flat. At open, nose_side should come in and down.
  • Page 20 Step 103. Step 104. Mirror on the other side with servo #7. Grab servo #8. Step 105. Step 106. Attach to nose_side with two m2x8mm bolts Servo arm position at closed. Step 107. Step 108. Attach servoArm_A. Prep arm_A with m3x8mm bolt and a washer.
  • Page 21 Step 109. Step 110. Attach arm_A to nose_side. Twice. Step 111. Step 112. Grab cheek. Attach using m3x8mm bolt and washer. Step 113. Step 114. Twice. Insert m3x8mm bolt and washer into cheek.
  • Page 22 Step 115. Step 116. Screw into servoArm_A. At close, all parts should line up and lay flat Step 117. Step 118. At open, they should come down and in. Mirror on the other side with servo#9. Step 119. Step 120. Re-attach brow_center_mount.
  • Page 23 Step 121. Step 122. Alignment at closed. Alignment at open. Step 123. Step 124. Find eye. There are two holes at the bottom. Step 125. Align led panel as shown and mark for those Step 126. two holes. Trim away the bottom along the printed part.
  • Page 24 Step 127. Step 128. Use two m2x8mm bolts to attach. Zip-tie cable as shown. Step 129. Step 130. Cable must run this way for clearance. Mirror the other side. Step 131. Attach the eye to brow_center_mount with Step 132. m3x6mm bolt. Marvel at your work for a bit, hard work is done.
  • Page 25 Step 133. Step 134. Time for wire management. Find wire_cheek. Insert wire from servo#9. Step 135. Step 136. Mount on top of servo #7 with two m2x6mm bolts. Mirror the other side. Step 137. Step 138. Grab wire_nose. Insert wires from servos 6, 7, 8, 9.
  • Page 26 Step 139. Step 140. Mount on top of servo #5 with two m2x6mm bolts. Grab wire_brow. Step 141. Step 142. Insert wires from servos 5, 6, 7, 8, 9. Attach to brow_center_mount with m2x6mm bolts. Step 143. Step 144. Zip-tie servos 3, 4 and eye wires together. Zip-tie servos 2, 5, 6, 7, 8, 9 together.
  • Page 27 Step 145. Step 146. Unplug all servos. Temporary un-screw servo #1. Step 147. Place wires into the channel under the servo Step 148. and re-attach the servo. Repeat on the other side. Step 149. Step 150. Plug all servos back in and remove tags. Grab wire_main.
  • Page 28 Step 151. Step 152. Attach to dome01 with four m2x6mm bolts Admire your commitment to clean wire work. Step 153. Step 154. Grab your slide switch. Mount to mouth with m2x8mm bolts Step 155. Step 156. On both sides. Grab your limit switch.
  • Page 29 Step 157. Step 158. Attach to jaw with m2x10mm bolts Zip-tie limit switch wire to mouth Step 159. Step 160. Zip-tie limit and slide switch wires to mouth. Zip-tie same wires to dome02. Step 161. Step 162. Grab your wired up Arduino Nano. Place into dome04.
  • Page 30 Step 163. Grab part “arduino“ and secure Nano with Step 164. two m2x4mm bolts. Do not over-tighten. Plug usb cables into power bank. Step 165. Step 166. Place the power bank over Nano. Grab part “battery“. Step 167. Step 168. Secure power bank with two m2x6mm bolts.
  • Page 31 Step 169. Step 170. Use m2x6mm bolts by the cheek. And another m2x6mm by the back. Step 171. Step 172. Connect all wires Zip-tie them all down. Step 173. Step 174. Grab wire_back. Attach with m2x4mm bolts...
  • Page 32 Step 175. Congratulations! You are all done and ready to wear your own Iron Man MK5 helmet.