The Tank - Custom Cosplay Helmet

Back in early 2021, I decided to teach myself how to use the CAD software Shapr3D in order to create my very own custom Mandalorian-inspired helmet. I was a student during covid looking to challenge myself with a new project like learning CAD, and Shapr3D stood out to me as an intuitive and exciting format to work on my iPad.

The first file I made, called “The Tank” was super rough. I knew next to nothing about CAD at the time and basically faked my way through building something that sort of resembled a helmet. I was able to achieve some general shapes, but remember feeling frustrated that I couldn’t yet clearly articulate my true vision for the design in 3D. Nonetheless, I decided to continue plugging away at it. I went to school for industrial design and continued teaching myself Shapr3D and other CAD software in my spare time. Since then, I’ve created hundreds of models ranging from other custom helmets to functional around-the-house designs and other props/cosplays. Shapr3D has been my go-to throughout. Finally, this month I decided to revisit my first model of “The Tank” and apply my original vision with the skills I’ve gained since.

The new build was incredibly different than the original. I started by lofting a series of profiles along guide curves (something I didn’t even know was possible when I made my first model) and created a shell of the helmet from that body. Then I performed a series of sketches and projections to imprint edges for the visor, cheeks, and back vent. I applied fillets and chamfers throughout the body to create the overbuilt, heavy feeling that I wanted this tactical cosplay helmet to have. The list of skills I’ve learned in these last five years of CAD work goes on and on. I’m quite happy with the final result, and seeing the juxtaposition of these two designs is really striking. I look forward to revisiting this design again in another five years!

This file includes both the original (2021) and updated (2026) versions of The Tank. I hope this project serves as a reminder that practice makes progress. Keep learning, keep trying!