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Home3D Printing3D Printing Film-High quality Props & Armor with The Damaged Nerd

3D Printing Film-High quality Props & Armor with The Damaged Nerd

Darrell Maloney, aka The Damaged Nerd

As soon as in awhile, we get the prospect to fulfill and get to know a designer with severe expertise, and Darrell Maloney, aka The Damaged Nerd, suits that description to a tee!

Initially from New York, and now residing in Virginia Seaside together with his spouse and their two boys since 2001, Darrell is rising as an incredible advocate and content material creator for 3D printing. As a graphic designer, Darrell had some expertise with inventive work. However after an damage in February 2017 that saved him out of labor, he watched a couple of DIY movies on YouTube about 3D printing by Uncle Jessy, and the remaining is historical past. He quickly purchased his first 3D printer and has been printing continuous ever since.

Thor's new ax from Avengers: Infinity War, Stormbreaker

Thor’s new ax from Avengers: Infinity Conflict, Stormbreaker

Darrell prints with a number of machines: the Creality CR-10, ATOM 2.5, Geetech A30, Robo R2, Dagamo and most not too long ago, the Peopoly Moai. To start with, like so many different creators, he began with PLA however rapidly moved to PETG after getting some wonderful outcomes.

One of many issues that set Darrell’s work aside is the time he takes in his post-processing to get actually outstanding completed items. Darrell explains, “Once I mannequin and 3D print my complete objective is when somebody sees the completed merchandise, that they cannot determine it as a 3D print. My put up course of method is fairly simple. I begin with sanding, and if the merchandise has a big floor space I’ll apply Clean-On XTC-3D, then sand. I begin with 100 grit then progressively transfer to 2000 grit. I exploit a number of primer filler and spot glazing putty to assist fill within the fantastic imperfections within the print with a view to obtain a clean floor. As soon as every part is clean I’ll then transfer on to color and add electronics, and so on., relying on the construct.”

A full, Thanos-sized Infinity Gauntlet, designed and printed by Darrell.

A full, Thanos-sized Infinity Gauntlet, designed and printed by Darrell.

Being a graphic designer, Darrell is skilled in a number of software program platforms that assist him obtain his objectives. Presently, he makes use of Cinema 4D – which has some drawbacks resulting from its lack of functionality to make correct measurements – however he’s been utilizing it for about 4 years. He additionally makes use of Simplify 3D, Cura, and Mesh Mixer. He’s additionally beginning to discover ways to use Fusion 360 and ZBrush.

A newly sanded and primed Gazerbeam helmet from The Incredibles film.

Along with his abilities and persistence, Darrell has made a number of commissioned items for cosplayers and costumers many instances over. From Marvel Comics iconic items like Thor’s Hammer, Mjolnir, to his new Infinity Conflict axe, Stormbreaker; in addition to the Infinity Gauntlet, objects from the DC Comics and Star Wars universes – a really giant vary of pursuits!

However understanding the method he makes use of doesn’t clarify why he takes the time to make such attractive fashions and creations.

“3D printing in a way turned remedy for me. On the time once I purchased my first 3D printer my sister had handed away, and it was onerous for me to take care of. I immersed myself in modeling, work, and 3D printing and I discovered that once I was engaged on ending an merchandise, I might course of my ideas and use that point to mirror. It aided within the therapeutic course of in a way. Lots of people complain about sanding however sanding turned (and nonetheless is) therapeutic for me.”

Designing the colour palette of the Nova helmet.

Regardless of this era of tragedy for Darrell, he continues to maneuver ahead in his work in modeling and 3D printing. “3D printing has lead me to locations I by no means thought I’d be capable of go and meet folks I by no means thought I’d be capable of meet. Once I began 3D printing I had no intention of it going so far as it did. It lead me to create a Youtube channel, and from there I used to be capable of set up a working relationship with Make: and have produced movies for his or her platform. I’ve additionally had the chance to work with on some superior collaboration initiatives, and to not point out the excellent people within the 3D printing neighborhood like Uncle Jessy, James Print N Play, Kuntry 3D and extra! The 3D printing neighborhood is by far probably the most useful and accepting neighborhood.”

As a relative newcomer to the 3D printing neighborhood, Darrell sees room for enchancment in getting the 3D printing phrase out to a fair greater viewers, particularly at an academic stage.

Priming the Nova helmet earlier than the paint goes on.

“I hope to see 3D printers and the idea of 3D printing in additional various areas, as frequent because it may be to people inside the neighborhood, it’s nonetheless a comparatively new idea to lots of people. I discover myself greater than usually explaining the idea to folks and exhibiting them movies to assist them grasp what it’s and what it may do. I feel what’s going to make 3D printing simpler and extra accessible is training and consciousness.”

Placing the ending touches on the Pink Hood helmet.

“There are superior folks like Josh from Design Make Educate who exit and educate and are on the bottom ground educating and bringing 3D printing consciousness to others. I’m nonetheless comparatively new, however as a result of there are such a lot of nice educators and people keen to share their information that I used to be capable of get into it. Like them, I hope to encourage people to get into 3D printing and perhaps faucet right into a ability set they by no means knew they’d.”

In fact, being a designer and having youngsters, there are ardour initiatives within the works. He’s within the means of designing a easy mannequin robotic package that his youngsters can put collectively and play with.

Darrell has additionally change into a full-fledged member of the crew for the reason that publication of this text – we will’t wait to see what he creates with the entire crew!

Darrell in his Knights of Ren helmet.

We sit up for seeing extra of Darrell’s wonderful creations sooner or later – we will’t wait to see what he works on subsequent!

To see Darrell’s work as The Damaged Nerd, go to and subscribe to his channel right here:

To see his work with Adam Savage and the crew, go to their channel right here:

Need to be our subsequent Hacker of the Month? Electronic mail, and inform us about your 3D printed creations – you can be featured in our subsequent publication. Hacker of the Month wins 3 free spools of PRO Collection PLA or ABS filament to additional their pursuit of 3D printing greatness!

Photographs courtesy of Darrell Maloney and Make: – captured as screenshots from The Damaged Nerd YouTube channel.



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