Faceplate mechanism

Iron Man Helmet Motorised faceplate mechanism

This page is about the motorised faceplate, check out the main project index for the rest.

Here’s some information on how I motorised my Iron Man faceplate. The helmet I used was one of my Polyurethane plastic casts.

Here’s two YouTube videos about the faceplate and eye lights, and making the helmet wireless, or scroll down for the written version with pictures

I decided that it would be pretty cool to motorise the faceplate for my Iron Man helmet, just like in the movies. This is how I’ve decided to go about it, I’ll be adding more updates and a video to this page as I finish the helmet up.

Firstly I cut the faceplate off one of my casts, the ‘widows peak’ part snapped off whilst I was doing so, so I glued that back on and reinforced it with a piece of aluminium – this will need to be quite a strong piece as you’ll see:

I’m using two standard sized servos for this, and some custom linkages that I made from aluminium:

These are attached to the ‘widows peak’ of the helmet and will also attach to the faceplate. This allows both angles and motion to be controlled. I found this was a bit wobbly, so I added another linkage on the other side of the servos, which is made from aluminium and two HDPE blocks with machine screws to make the hinges:

This gives a good range of motion, and although I could have used smaller servos, the helmet still fits me and my eyes are at the right height:

Some primer and sanding/filling/painting, just need to sort out the electronics and line it with foam:

I’ve made a nice foam liner around the seam line of the faceplate, this means it has something to rest/fit against when it comes down. I’ve done some testing with a Pololou Mini Maestro servo controller controlled by a Picaxe18 for now. This is the same as Android 11.

I have now made the helmet entirely wireless, with everything on board. In the picture there are 6 AA batteries, a Picaxe-08 board, a servo controller, a 3A adjustable regulator to power the servos, and 5V fixed regulator for the electronics, and an Infra-red receiver. The transmitter will also be based around a PICAXE-18 and built into the suit.