Headset Design and Construction

Moira’s headset is a set of sci-fi headphones that wrap around the back of the head. It is positioned such that the arch curves behind the back of the head, seemingly floating.

The model was developed in Autodesk Fusion 360 using the game model as a base, then adjusted to fit the shape of my head using a 3D-scanned mannequin head. The headset model was made hollow to fit the electronics - a covering will be added later to hide the lights and diffuse them. The headset was then 3D printed in PLA plastic.

Electronics

The headset is illuminated on the inner surface by a strip of Neopixels installed inside along the back curve. These are controlled by an Arduino controller (Adafruit ItsyBitsy), powered by a 3.7 V LiPoly battery with a 3.7V to 5.2V conversion board (Adafruit Powerboost 500). These modules are tightly packed into the wider ear portions. A pushbutton switch added between the battery and the power board easily switches the lights on and off while worn. The battery is hidden by slipping it into the wig just behind the ear.

After installation, a layer of polyethylene foam was added over the top to seal in the LEDs, hide the electronics, and diffuse light into a clean, uniform glow.

Surface Finishing and Paint

The headset was finished using same method as the rest of the armor:

• 220 grit light pre-sanding/scuffing

• XTC-3D double layer

  • First layer ultra-thin

  • When tacky-cure, apply another thin glossy layer

• 400 grit full surface sanding

The paint was also airbrushed in the same method as the armor:

• 3 coats Vallejo Gloss Black primer (74.660) with Airbrush Flow Improver (71.562)

• 2 coats Vallejo Model Air NATO Black (71.251)

• Allow the acrylics to fully dry (at least 24 h)

• 3 coats Rustoleum Gloss Clear

For the metal accents in the ears:

• 3 coats Vallejo Gloss Black Primer (74.660) with Airbrush Flow Improver (71.562)

• 2 fine dust coats of Vallejo Metal Color Aluminium (77.701)

Rigging

Magnets were installed on both sides of the headset on the foam diffuser and sewn into the underside of the wig behind the ears, to create the illusion of the headset floating. The headset anchors itself to the side of the head and is fully supported by the wig. This allows the back of the headset to curve back behind and away from the head.