Part 3 – welding with a jig
In order to ensure the ear muff, jaw pieces and rear top section all join act exactly the right angles, CMDR Antonia had modelled an alignment jig. I printed a left & right jig during the day and then in the evening put all the parts from one side into their respective jig and carefully welded them together with spots of resin and the UV torch. Once the parts were fixed, I removed them from the jig and added a thin application of resin in all the cracks and joins, effectively making the parts a single piece.
With that done, I printed the rear cross sections. Again I needed to print these in two halves and then weld them together. This was getting easy now, so having done that, I welded the rear cross section to the main helmet.