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YOU CAN 3D PRINT IRON MAN'S MOTORIZED HELMET

Servos open and close the faceplate and the eyes are LED panels: 28 printed parts, an Arduino Nano and a servo driver board.

by Box and Loop

FULL CAD BOM FIRMWARE DOCS

Workshop

Built withArduino3D printing

difficulty
●●●○○
time
a weekend-plus
license
CC BY 4.0
repo
repo 0 stars

WHAT YOU’LL NEED

Videos
1
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COMPAREE VERDICT

This is a wearable Iron Man Mark 5 helmet whose faceplate opens and closes on servos, with flexible LED panels for the eyes and a USB power bank inside, so it runs without a cable. The download is complete: 28 STL files, the Arduino code, a parts list and three PDF guides for printing, wiring and building, under a licence that allows commercial use. The creator also published an 11-minute assembly video that walks through every servo and every bolt length in order. The electronics are simple: an Arduino Nano, a PCA9685 servo driver board, two kinds of servo (a slim metal-gear Corona DS-239MG and SG90 micro servos), a capacitor, a limit switch and a power switch. The part most likely to go wrong is the faceplate mechanism: the video shows the servo arms have to be lined up by hand, some corners trimmed for clearance and servos repositioned to fix misalignment. Note that the video starts after the printing, the code upload and the wiring are already done, so read the wiring guide first. If you have built a multi-part print with small bolts and a few servos before, you have the skills.

GOOD TO KNOW

  • —28 STL files on Thingiverse under CC BY 4.0. You can sell prints or derivatives with credit.
  • —Arduino code, a parts list and three PDF guides (printing, wiring, build) are included in the download.
  • —The parts list names exact parts with shop links, including the servo models and the power bank (Adafruit 5000 mAh, two 5 V outputs).
  • —The electronics are an Arduino Nano and a PCA9685 servo driver board.
  • —The 11-minute build video is a step-by-step assembly guide with chapters for each servo and bolt size.
  • —The same files are also offered on Thangs and Cults3D.

Parts to buy

12 items

From our check of the build. Exact quantities and part numbers are in the creator’s BOM.

  • Arduino Nano (Every or classic)Find
  • PCA9685 servo driver boardFind
  • Right-angle header pinsFind
  • Corona DS-239MG slim wing servoFind
  • SG90 micro servosFind
  • 2200 uF capacitorFind
  • Flexible LED eye panelsFind
  • Limit switchFind
  • Power switchFind
  • Adafruit USB power bank with left and right-angle USB cablesFind
  • M2 boltsFind
  • M3 countersunk bolts and M3 washersFind

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Can I build this?

Print28 STL files for the helmet shell, faceplate mechanism, internal mounts and eye pieces
BuyArduino Nano (Every or classic), PCA9685 servo driver board, right-angle header pins, a Corona DS-239MG slim wing servo, SG90 micro servos, a 2200 uF capacitor, flexible LED eye panels, a limit switch, a power switch, an Adafruit USB power bank with left and right-angle USB cables, M2 bolts, M3 countersunk bolts and M3 washers. Optional: JST connectors.
Tools3D printer, screwdrivers or hex keys for M2 and M3 bolts, a soldering iron for header pins and wiring (or JST connectors), a craft knife for trimming parts and LED panels, and a computer with the Arduino IDE
SkillsIntermediate: printing a large multi-part model, uploading a sketch to an Arduino Nano, wiring a servo driver board from a diagram, and careful assembly with many small bolts.
Timea weekend-plus: printing 28 parts takes the longest, then wiring, then the assembly, which follows the 11-minute build video step by step.
Cost$$: mostly the servos, the servo driver board, the power bank and the filament for 28 parts. The creator does not give a total.
SafetyLow-voltage USB power only: everything runs from a 5 V power bank, no mains. The lithium cells stay sealed inside an off-the-shelf power bank. Keep fingers clear of the faceplate while the servos move it.

Build at your own risk. Projects involve tools, electronics and sometimes mains voltage — follow the creator’s safety notes.

Videos

How to build Iron Man MK5 helmet11:21

The creator's step-by-step assembly guide (November 2021, about 3.9 million views). It shows which bolt goes where and how to fit each servo, but it starts after printing, code upload and wiring are done; those are covered in the PDF guides in the download.

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Start here

Navigation into the creator’s own docs — we don’t rewrite the guide, we route you to the source.

  1. 1.Download the files from Thingiverse (28 STLs, Arduino code, parts list and three guides (printing, wiring, build), all under CC BY 4.0)
  2. 2.Read the printing guide and start the prints(It is one of the three PDFs in the download. Check the largest parts against your printer bed in your slicer first)
  3. 3.Order the electronics from the parts list(Arduino Nano, PCA9685 servo driver, DS-239MG and SG90 servos, a 2200 uF capacitor, flexible LED eyes, a limit switch, a power switch, a USB power bank, and M2 and M3 bolts)
  4. 4.Upload the code and wire it using the wiring guide(The build video assumes this is already done)
  5. 5.Assemble along the build video (It goes servo by servo and names the bolt length for each step)

Resources

Documentation, files and community threads for this build — we link straight to the original sources and never rehost the creator’s files.

KNOWN ISSUES

  • The faceplate mechanism is the fussy part. The build video shows lining up the servo arms physically, fixing misalignment by moving a servo, and trimming a corner for clearance. Expect some test-fitting.
  • There are two kinds of servo on the parts list: a slim Corona DS-239MG metal-gear wing servo and SG90 micro servos. The mounts are made for these, so check the dimensions before you swap in anything else.
  • The build video assumes everything is already printed, the code is uploaded to the Nano and the electronics are wired. Do those steps with the printing and wiring guides first, or the video will not make sense.
  • The assembly uses many small bolts in different lengths (M2 from 4 to 10 mm, M3 from 3 to 10 mm, plus M3 washers). Sort them before you start; the video names the right length at each step.
  • Do not skip the 2200 uF capacitor on the parts list. A capacitor like this steadies the supply when several servos start moving at once.
  • The flexible LED eye panels have to be cut to the shape of the eye openings, so buy them knowing you will trim them.

Can I wear this, or is it just for display?

The creator describes it as fully articulated, wearable and chargeable. It runs off a small USB power bank that sits inside the helmet, connected with a right-angle USB cable.

Do I need to know how to code?

No. You upload the included Arduino sketch to an Arduino Nano (the parts list says the Every or the classic Nano both work). The build video's advice is to line up the servo arms physically rather than fixing them in code.

What licence are the files under?

CC BY 4.0, which means you can remix, sell prints, or use it commercially as long as you credit Box and Loop.

How big does my 3D printer need to be?

The creator does not give a minimum build volume. The helmet is split into 28 separate parts, so load the largest STL into your slicer and check it fits your bed before you commit.

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Discussion1

FROM THE COMPAREE TEAM

The faceplate is driven by servos and has to be aligned by hand during assembly. Would you build the motorized version straight away, or print a static display helmet first?

CompareeTEAM4d agoedited

Practical notes from our verification: the Thingiverse listing describes 28 STL files, the Arduino code, a parts list and three PDF guides for printing, wiring and assembly, under CC BY 4.0. The build video starts after printing, uploading the code and wiring, so work through the printing and wiring guides first. The fiddly part shown in the video is the faceplate mechanism: the creator aligns the servo arms by hand during assembly and trims some parts for clearance.

Box and Loop

Box and Loop designed this wearable motorized Iron Man Mark 5 helmet and released the STL files, Arduino code, parts list and three guides for free. Their step-by-step assembly video from November 2021 has been viewed about 3.9 million times.

Star the project on GitHub

DISCLAIMER

  • Comparee is not the author of the projects featured here. All rights to each project belong to its creator — every page links to the original source, and we never host creators’ files.
  • Information is provided without warranty and may become outdated as projects evolve. Prices are indicative bands only — always check the creator’s parts list for current costs.
  • Building and operating any project is at your own responsibility. Protective equipment, safe workshop practice and compliance with local regulations are the builder’s responsibility.
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