CNC Machining a Clone Trooper Helmet

For this CNC machining assignment, I picked a Star Wars Clone Trooper-style helmet from the Noun Project. I turned the SVG into a physical piece using both the Shapeoko and Nomad, then post-processed it to get a white helmet clone trooper look.

Choosing the File and Preparing the Design

I downloaded the Clone Trooper icon by Zachary J. Savoy from the Noun Project (https://thenounproject.com/icon/storm-trooper-49992/). After importing the SVG into Carbide Create, I scaled it to fit the wood stock and set up the job parameters. I defined two depths, one for the pocket cuts and one for the outer contour, so the helmet details would stand out.

Creating the Toolpaths

I built pocket toolpaths first to define the recessed black areas of the helmet. After that, I created the contour toolpath to cut the outline free from the stock. The file was then exported as G-code for each machine. One version was cut on the Shapeoko and the other on the Nomad so I could compare results. Both machines handled the geometry well, but the Shapeoko felt better suited for the deeper passes.

CNC Machining

I set up each machine with a 1/16-inch end mill, zeroed the tool, taped and clamped down the wood, and ran the jobs. Each cut completed without issues. The Nomad produced cleaner edges on small details, while the Shapeoko removed material faster.

Post-Processing

Once both pieces were cut, I sanded the faces and edges to remove the tool marks and tabs. I spray-painted the surfaces white, let them dry, and added a clear coat for a smooth finish. To bring out the helmet features, I mixed resin with black dye and filled the recessed areas. After the resin cured, the contrast matched the look of a clone trooper helmet.

Cost Breakdown

The 2 wood blocks cost $8. Spray paint and clear coat added $1 combined. The resin and black pigment came from a larger batch, so the fraction I used (less than 1/4 oz) was $0.10. Consumables like sandpaper added $0.50.

This project took me 3 hours to complete. At $10/hr, total labor cost was $30.

The total material and labor cost came out to about $39.60.