Helmet In Cardboard before application of Jesmonite

Visor made from 3mm iridescent acrylic bent over a former.

Pepakura Helmet

Cardboard modeling is not new but a piece of software that translates an STL file or a 3DS file into a working net with glue tabs has to be a bonus. The software comes in two forms an editor (Under Licence) and a player. The advantage to this is that you can limit the number of licence's you buy but readers are free for school or home use. Having used the editor to make the net the reader can then be used to help with assembly in school or at home.

The units can be scaled to fit any size of user. Take a measurement and add 60 mm for padding inside the model. Then enter the measurement into the unfold option of pepakura and it will automatically scale the other two dimensions and then unfold the model out onto a number of sheets, depending on the size you have set the paper to. Using the Gravograph 900 we were using card sheets 450mm by 610mm. On the laser settings change the fold settings to dot cutting. this will ensure that the card folds but is not weakened in any one direction.

It can be used for design mastering or the production of props for amateur productions or media courses etc. etc.

Pepakura is Japanese for Paper Craft. It is also the name of a piece of the downloadable software that will allow the construction of the original file to any scale. The system interfaces to a laser cutter as a printer driver and makes assembly the only real problem. Currently enthusiasts would print out and then cut these pieces out from card and then assemble then into the final article subsequently strengthening the card with resin and fibre sheet. Two non toxic resin product are now available that can be used in schools. Jesmonite and AquaResin. Using a Laser cutter makes the whole task a pleasure instead of a labour of love.

This video shows the strength of Jesmonite for all those who have not met the new Non Toxic Resin. It can be mixed with colours including metal powders and then machined to relatively high accuracy.

This software in conjunction with a laser cutter will revolutionise the art department, D & T Rapid Prototyping now becomes a low cost exercise and the possibilities for media courses and school plays with regard to props and scenery is fantastic.

This software is open to the public as shareware so you can download and try it freely although some advanced features are limited until you purchase a licence key.

This Movie was made by amateurs using costumes made with the Pepakura system and a lot of home crown CGI.

The watershed point has been passed with regard to the home made movie and the only restrictions is the time and commitment that the group will put into a project. High quality movies are within the reach of anyone with the time and determination. Visit www.IndyMogul.com and see how special effects can be done on the cheap.

From the Halo3 the Microsoft Game, this cardboard replica is the first stage in the production of a film prop using the technique know as Pepakura - Translation from Japanese - Paper kraft.

The file was downloaded from the 405th website and printed out on the LS900 laser printer marking hill folds with chain doted lines and valley folds with dot dash lines.

The result being a very accurately cut card master that was then assembled using the software to guide your construction and a glue gun.

The next stage is to increase the mechanical strength with the application of Aqua Resin or Jesmonite and fibre tissue any fibre will help with the strength and if you wish to avoid fibre glass denim and textiles will also work well in the resin base.