Hello. Welcome to another behind-the-scenes blog. In this one, we will walk you through the creation of the wearable helmet from the Classic DOOM Helmet Collector’s Bundle.
Let’s get to it.
STEP 1: PRE-PRODUCTION
We started off strong with the 3D model of the helmet from DOOM Eternal’s Classic Skin. This took care of accuracy but came with a set of engineering challenges.
Oftentimes, what Doomguy wears in-game won’t work as it is for real people. In order to make the replica wearable, we:
- enlarged the entry hole,
- re-created the interior with more clearance for the nose, ears, and overall head girth, and
- added connections for the head strap system.
On the outside, the final 3D model looks virtually indistinguishable from the in-game helmet.
STEP 2: PROTOTYPE
The previous step was fun, but this one takes it to another level. After letting the 3D printer do its work, we finally got to hold and wear a prototype of the helmet. But before we could goof around and pretend to glory kill our coworkers, we had to please DOOM’s developers.
Working closely with them, we hand-painted the helmet to make sure that everything was believable, accurate, and functional.
As if we ripped it straight out of hell!
The design for the head strap system was a success.
Above: A simple and effective way to keep your helmet on
We also needed to balance the look of the visor with its opaqueness. We wanted to make sure you could still see properly when you put this on.
Caption: The visor meets visibility requirements for safety.
STEP 3: PRODUCTION
With the prototype approved, it was time to take it to the factory.
To produce the helmet’s complex shape, we split it into parts with their own separate molds. Here’s what one of them looks like:
Each mold was cut from solid steel and weighs as much as the engine block of a car.
We used mini cranes to load the molds into the plastic injection machine.
Inside every mold is a series of posts that ensure each half is aligned and fits seamlessly with the other. Then we injected molten ABS plastic into the mold under hundreds of pounds of pressure to ensure it fills the entire cavity quickly before hardening.
If you’ve ever assembled a plane or car model kit before, you’re familiar with the plastic tubes that you had to remove to collect the model’s parts before assembly. These are called ‘sprues,’ which are partially where the plastic flows into the mold.
Above: DOOM Classic Helmet Sprues
When the plastic cooled, we used the ejection pins inside to push the completed part out. The next step was to remove the sprues and begin assembly.
Above: Preparing the parts for assembly
Once we had all the parts assembled, all that was left to do was to paint each helmet by hand.
And there you have it. Now you can wear Doomguy’s very first helmet!
Get yours and more exclusive DOOM collectibles in the limited production Classic DOOM Helmet Collector’s Bundle.
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