With the Nissan collaboration in place, Lucasfilm approached frequent partner Gentle Giant Studios with the task of creating the helmet replicas. Known in the entertainment industry for delivering exceptional quality props, digital assets and collectibles within tight deadlines, our 3D Systems Gentle Giant artists were more than up for the challenge of crafting and delivering over 5,400 detailed, high quality replicas with just 3 months on the clock. Our digital modelers got to work right away to create a 3D printable helmet model and base. With photographs of the official Star Wars costume and digital scan data as our guide, we sculpted the helmet in 3D from the ground up.
Once fully modeled as a single unit, we analyzed the data to determine where the helmet could be divided into separate pieces for manufacturing. Our artists and on demand manufacturing experts are well versed in the manufacturing constraints of mass production, and brought their insights to bear on this project to deliver a stunning and seamless final piece. Once complete, the helmet files were sent to the Stereolithography (SLA) printer to create a first article helmet in the final dimensions (15”H x 11.5”D x 10”W). The accelerated design verification process enabled by 3D printing was critical to keeping production on schedule.
Once approved, these SLA prototypes (helmet components and base) were used to create the master fiberglass production molds. Using these molds, our team was able to execute a low volume production run with high quality finishing to meet Nissan’s quota and deadline.
Rogue One: A Star Wars Story came to theaters December 16, and starting late November the 2017 Nissan Rogue: Rogue One Star Wars Limited Edition was available for purchase. The exclusive Gentle Giant Studios created Death Trooper replica helmet is available only to owners of the Nissan Rogue Limited Edition (starting at $28,950). According to Nissan, only 5,400 will be sold, but “unlike the Death Star, when these are gone, [they] won’t be building them again.”