This is our first in-house design and print. We spend around 70 man·hours to finish this project. Altough it’s far from perfect, we’re proud of how it turned out. We present you our Pyke Ashen Knight mask.

Together with AMI Procedural we modeled the mask in Blender to match the appearance of the in-game model and of the fan-art sketches. We used transparent PETG to diffuse light from a RGB LED stripe, slided through ad hoc channels in the back of the mask. We used plaster, spray paint and acrylic paint to cover the front and not let light pass. Some areas still let light shine through, so we painted the area also on the back and that solved the problem.

We first made tests with slices of the mask to test tolerances without using much material. That allowed us to make due corrections and proceed to print the full model.

It was print time. We spent way too much time optimizing the settings to print faster but got there in the end. The job lasted until dawn and waked me up when it finished. Supports looked very unstable but what is considered a flaw of PETG became an advandage in our situation. All those strings held the supports together like a spider web; and even though some of them were literally floating they managed to get to the top and support the print.

Altough there were many defects it was overall good and very sturdy. We proceeded to decorating. We applied plaster all over the front, especially on holes of the surface.

After that we applied sandpaper to smooth the surface. We repeated this cycle until we were satisfied.

Then it was time of painting. We applied paper tape to the inside of the eyes and spray painted black the front of the mask. The residual roughness of the plaster gave the surface a worn out look, appropriate for the battles it endured. We painted the border of a metallic blue by hand.

After that we mounted the LED stripe and attached it to a IR controller. We applied some pieces of foam to ease the contact with the forehead and the nose. We also attached an elastic band through holes we modeled.

The finishing touches were sticking the silver symbol on the front and sticking a net for the eyes. We repurposed a mosquito net that had a good appearance; depending on the exposure of the camera that let the face of the wearer appear or became just white like in the game.

Control the color with a IR remote. And that was our custom made Pyke Ashen Mask. The client wasn’t very satisfied but that’s way more than enough for what we got paid.

Find more photos and other projects on: https://www.instagram.com/plasticdreams.xyz/