I'm a long time fan of the Halo series and it's been a dream of mine to make the armours from Halo Reach 3D printable. I spent roughly 3 years modeling each and every piece of Spartan armour from scratch using the old models as a reference
Because of the low-poly nature and texture resolution of the in-game models there were many details that I had to enhance and embellish based on what I assumed the original artist was attempting to render.
Certain texture details and physical angles just could not exist in 3D space so the goal was to strike a fine balance between a geometrically clean model while also trying to be as accurate as possible to the old shapes
3Ds Max was my primary tool. I'm proficient enough in Max to produce any hardsurface shape I need for this project.
Because of the nature of 3D printing, each model has to be a single monolithic piece and has to be very high poly so as not to appear faceted once printed. They must also be an airtight STL or OBJ file. LOTS of boolean operations done mainly in 3D coat.
I designed each and every piece to be modular. Meaning every shoulder, chest, leg, and wrist attachment slots on and marries up to the physical geometry of the base armour.
After a ton of work and a lot of time I finally produced every single piece of armour and accessory from the original game including a few pieces from the DLC of the Master Chief Collection
I also decided to break up the Military Police helmet into it's other variants