Download STL files from the Gallery.

Before printing all the parts you should print the CALIBRATOR, to check if your parts will fit together. If you have a very hard time putting those parts together, adjusting the horizontal expansion setting of your slicer software can solve that, this setting can vary depending of your slicer and printer but users report to set it at -0.15 is a great place to start.

The size of the molds are big and require a big print area. Check if it fits your printer prior starting building the head. Standard 220x220mm bed size will do the job.
The silicon reference is Smooth-On 00-10. One skin requires about 500Gr You can color silicon with oil paint or pigments. You can also add flocking to give it skin touch. Because skin color is very light and slightly transparent, you only need to add a very little amount. Mainly white, then some red and a tiny bit of yellow.
15 servos JX PDI 1109MG (avoid using cheap SG90, they won’t last long)
2 servos JX PDI 6221MG
28 magnets neodyme 10×1.5mm
1 or 2 micro camera(select the type2 with auto focus) https://fr.aliexpress.com/item/1005004200917640.html?spm=a2g0o.order_list.order_list_main.76.40465e5b637U38&gatewayAdapt=glo2fra

i2Head tutorial:

Here is the list of parts and the number of prints needed for the head:

    • 1x BottomTeeth
    • 1x CheekPuller
    • 1x EarLock (add support)
    • 1x EyebrowSupport
    • 1x Eyebrow
    • 1x FaceHolderLeft
    • 1x FaceHolderRight
    • 1x ForHeadSupport
    • 1x ForHeads
    • 1x GearHolder
    • 1x JawHinge
    • 1x JawPiston (add support)
    • 1x JawSupport
    • 1x Jaw
    • 1x LowBack (compatible from original head)
    • 1x MainGear (compatible from original head)
    • 1x UpperLip
    • 1x Ring (compatible from original head)
    • 1x ServoGear (compatible from original head)
    • 1x SkullServoFix
    • 1x TeethTopHolder
    • 1x TopBackskull (compatible from original head)
    • 1x TopTeeth
    • 1x TopskullFront
    • 1x Topskull (compatible from original head)
    • 1x servoAdapter (only if you use a smaller servo than HS805BB for to rotate the head)
    • 1x servoHornAdapter (only if you use a smaller servo than HS805BB for to rotate the head)

Print with an infill of 30%, wall thickness 2mm, check for parts that needs support.

  • Here is the list of parts and the number of prints needed for the mold, select Male or Female:
    • 1x InnerMiddleMold
    • 1x InnerSidesMold
    • 1x OuterBottomMoldFemale (add support)
    • 1x OuterBottomMoldMale (add support)
    • 1x OuterTopMoldFemale (add support)
    • 1x OuterTopMoldMale (add support)

    Print with an infill of 15%, wall thickness 2mm, check for parts that needs support.

  • The three innermolds should not be glued or attached to each other, otherwise you will not be able to release the skin and inner molds from the outer molds.
  • I applied sprayed car filler plus some sanding and finished with a clean car filler spray. I had to go first with grain 80->sprayed->150->sprayed->400->sprayed a last layer from far to create a grainy skin effect.
  • The purpose of the angled middle inner mold is to be able to slide out easier once the silicone is cured
    The three innermolds are setting themselves in the outermolds because of the two bolts, you can use clamps if you prefer.
  • Use hot glue or kinder dow to seal temporarily these seams to make sure the silicone won’t run out from the molds.
  • When pouring the silicone, make sure that it’s filled until you see it in the ear vents.
  •  

    Tutorial in progress


Assemble together MainGear and NeckPlateHigh with 4 screws (3mmx16mm).

Add ServoGear on the top.

Slide over the GearHolder, make sure it can rotate freely in both directions.

Glue together GearHolder, FaceHolderRight and FaceHolderLeft.

Press push in the two JawHinge. If it is too loose, glue them in.

Mount TeethTopHolder with 4 screws (3mmx16mm).

Set two servos with their horns and make sure they are preset at 90° in your software.(rest position)

Fix to the servo horns the two CheekPuller.

Assemble TopTeeth with two screws (3mmx20mm).

Get the two JawSupport.

Fix the Jaw with 4 screws (3mmx10mm + bolts) or just glue the parts together.

Mount with 2 screws BottomTeeth to Jaw. (3mmx16mm)

Clips the assembly on the JawHinge. It should move freely. The teeth should close nicely.

Add LowBack with two screws. (3mmx16mm)

Press push the Ring making sure the holes align with the holes of MainGear. Add only 2 screws from the sides. (3mmx16mm)

If you have a HS805BB servo, preset the horn at 90% in your software. Add 2 screws ( small wood screws) between the horn and the ServoGear.

If you have a Smaller type servo (JX PDI 6221MG 180°), preset the horn at 90% in your software. You need to assemble it with the ServoAdapter and ServoHorn Adapter. Add 2 screws ( small wood screws) between the horn and the ServoGear.

Press over the SkullServoFix. Use 4 screws (wood screws) and fix together the SkullServoFix, the servo and GearHolder.

Mount the horn to your servo (JX PDI 6221MG 180°) and preset it at 90° in your software. Attach JawPiston with 4 screws. (small servo screws). Insert JawPiston into NoSupport. When the servo is going to rotate by software, it needs to be able to open and close the jaw.

Add a servo as shown below with two screws (small servo screws). Make sure to preset the servo at 90° in your software and mount the horn.

Attach to the horn UpperLip with 2 screws (small servo screws).

Add the left eye assembly. And fix it with 4 screws (small wood screws).

Add the right eye assembly. And fix it with 4 screws (small wood screws). You have a space above the eye assemblies to set the camera driver board with 2 small screws. Make sure to pass the camera ribbon (cable) between the eye and driver board  and allows the eye to move freely.

Add the ForHeadSupport with 2 screws (3mmx16mm).

Glue or use 4 screws to mount EyeBrowSupport with ForHeadSupport.

Add both servos for the eyeBrows with screws (small servo screws). Make sure to preset the servos at 90° in your software and mount the horns.

Fix each EyeBrow to the horns with respectively 2 screws. (small servo screws)

Add servos with screws to ForHeadSupport. Make sure to preset the servos at 90° in your software and mount the horns.

Fix each ForHead to the horns with respectively 2 screws. (small servo screws)

Mount the 2 TopBackSkull respectively with 2 screws (3mmx16mm).It is best to add bolts on the inner side of TopBackSkull. I heat up the bolts with a small flame and press it with pliers into the bolt cavity, making sure it cannot fall out.

Same process for TopSkull. The 2 top screws are (4mmx20mm)

Same process for TopSkullFront.

Same process for TopSkullFront.

Add EarLock on both sides respectively with a screw (3mmx16mm).

 

Note that the i2Eyes are synced to the original eyeX and eyeY.

Also the i2Eyelids are synced to the original eyelids servos.

This will probably change in the future, but for now it allows to use standard gestures to operate the i2Eyes and i2Eyelids.

Here is the listed names for the new servos:

## the eyes
i01_head_eyeLeftUD
i01_head_eyeLeftLR
i01_head_eyeRightUD
i01_head_eyeRightLR

## the eyelids
i01_head_eyelidLeftUpper
i01_head_eyelidLeftLower
i01_head_eyelidRightUpper
i01_head_eyelidRightLower

## the eyebrows
i01_head_eyebrowRight
i01_head_eyebrowLeft

## the cheeks
i01_head_cheekRight
i01_head_cheekLeft

## the upper lip
i01_head_upperLip

## the for head
i01_head_forheadRight
i01_head_forheadLeft