This is another Star Wars project: Han Solo in the Carbonite, from The Return of the Jedi. It's been a while that I wanted to have something like that.

This model is based from a quick scan made during the Star Wars identities exhibition in Paris (like the ISD Avenger), then I re-sculpted most of it and I'll 3D Print it, then doing some painting and probably a background/environment.

Scan 3D

As always, scanned through photogrammetry, then sculpted with ZBrush. The goal is to do a 1/12 scale one (190mm)

Bellow is the original scan in PhotoScan. It looks nice, thanks to the display of the texture (which was for me the real big help).


And the scan in ZBrush, before cleaning. The main shapes are here, but on really fine details that I'll have to resculpt everything.


Cleaning the scan in ZBrush

As soon as I imported the scan in ZBrush, I started the cleaning process, by reprojecting the details on a DynaMesh version, the using ZRemesher to quickly create a retopology, creating the UVs with UVMaster and finally reprojecting the color through Photoscan. It was enough to help me projecting some details grabbed from the texture (from left to right, below).

As you can see, this technique is very convinient to do a quick edit, but it has its negative side, like displacing the shadows which are very strong on the texture. You can see that on the right hand, under the fingers (in the circle).

Then came the long process of recreating the different forms, refining some parts and adding or rebuilding all the fine details. Using this texture projection doesn't do everything by far, but it is very helpful as it elps respecting the original model. You have the good proportions, the good location for the details, it avoids you a lot of mistakes and try and errors.

However, I had to look a lot at my references photos for rebuilding broken parts like hands and face. Having a lot of photos was something great as finding good reference in high quality on Internet was almost impossible.

The controls on the side. I think the model at the exhibition is a replica of the movie, not the original as the control are different. In the movie, this part just goes more out of the main shape, not as inside as it is in my screenshot. This is something that I need to fix...

Some closeup... Don't ask me why I totally screw up the nails. I didn't notice until now. It won't be visible in the 3D print, but well... I'll need to fix that!

Let's hope that the 3D print will be enough details. Perhaps I should have increased the contrast in the details, especially the carbonite part...

3D Printing

The 3D print has been a success, no issue. The quality is pretty good even if I divided to go with the mid-resolution (50 microns).

This is "Han Solo in the Liquid Resin" 🙂 Before the IPA Alcohol bath to clean all the remaining resin. Of course, all the supports will be removed. Orientation and preparation are important as you don't want to have them in the visible part of the model.

Here is a screenshot of the models in Preform. As you can see, the main one bearly fit the printing maximum volume.

And this is the result of a quick grey primer color pass. Not so bad 🙂

The side. Yes, some controls have been inverted. Not a big deal, it was just for the photo 🙂

Some closeup on the controls. Details are very good. It is not visible in the photo because of its size, but you can see the Philips screw heads on the corner 🙂 This Form2 printer just kills me 🙂

A closeup on the side of the print. As you can see, the layers are visible, but a little bit of sanding will easily remove them, especially after using some primer. But to be honest, after the metallic grey paint layer, I don't even think sanding will be needed, especially at this scale...


This is the final model with a mid silver gray Tamiya paint plus a panel line black. It was the first time I was using the Panel Line painting from Tamiya. Next time, I'll have to use a layer of coating first. But I'm really pleased with the end result!


This project is done for me... but I hope to build a kind of diorama in the future, the one corresponding at Han Solo in Carbonite in Jabba the Hutt castle... but later!

  1. Marc Taylor 6 months ago

    Hello, is that file available?

  2. Steve 5 months ago

    Hi is the file available for purchase please.

  3. Jason 2 months ago

    This model is really cool! wonder if the model is aviable for download? I will credit to you, hope you can exchange the model.

  4. Author
    Thomas 2 months ago

    I am sorry, this file is not available for purchase or for download 🙂

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Thomas Roussel - 2008 - 2018

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