Creating a front (face) and rear head cover

[am10g11]

Hi everyone. I am trying to find a face cover for a demo solid model that is:

>> thin

>> has two parts (front and back) that click together 

>> I want the cover to follow the face ups and downs, The eye, nose holes, mouth, ear, etc. Mould of some some sort, if makes sense.

I know Derive could be a way. However dont want the drive the face out of a square box. Hope it makes sense.

Any help is appreciated.

Thanks,

[JDMather]

@am10g11 

Attach the *.ipt file(s) of what you have attempted so far.

[am10g11]

Hi, I have attahced 4 files (all in a zip) for the DERIVE approach for the front. This is the only way I know but its far from what I am looking for, though. I am looking for somthing like facemask/shell, thin and still maintaining the face shape.

Files attached include: box (ipt) + face (ipt) >> human face (assembly) >> derived part (front mould using derived)

[JDMather]

@am10g11 

This is from stl

Stl is rubbish.

Did you not notice that there is not a single curve in the geometry? Not one!

All faceted planar triangles and straight lines.

I recommend that you take a look at Autodesk MeshMixer for this.

[am10g11]

I agree @JDMather . I am struggelling to find a best way to convert it to a solid file. I used Fusion360, which clearly did not work. Not very familiar with MeshMixer but gave it a try. It gives back an .obj file as solid that not sure how to use it!

I have attahced both the meshmixer file and the generated obj files here.

Can you help me understand the relationship between having a solid file and creating a mask that I am looking for? Arent they supposed to be two separate parts?