Wearable Episode VII StormTrooper Helmet

by Geoffro, published

Wearable Episode VII StormTrooper Helmet by Geoffro Oct 27, 2015

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It's not that you are making money off my work, it is that you are not giving any credit.
Have a look at this youtube video. That's Adam Savage talking about my Storm Trooper mask he bought in pieces. Do you think it would have been nice if he knew who made it and possibly could have just given some credit? bit hard when it's stolen and sold without credit. I think it's clear it was my one as I screwed the scale up to start with and it was the skinny version (without the add ons) so yeah it's very dssappointing when you find things like this.

Update 28/10/2015

I have made a small modification to parts 3 and 4 - if you printed them already I am sorry, but don't worry, it was an addition not a fix! :) I put the small details that go on the sides of the helmet (the little round bits)

I also have uploaded the full helmet in one massive STL, if you have a printer big enough to print it in one go, then I envy you!

As promised to many people, here is the Episode VII wearable helmet. This is considerably different to the other smaller Ep7 helmets as it now follows the contour more of what we have seen in the trailers.

I have based the size of this off my previous Stormtrooper helmet (which was 33cm wide) this new one is 30cm wide as it doesn't have a rebreather on both sides on the new version.

All pieces have been plated ready to print, checked for errors and all parts triple checked they are the right number etc. The youtube video explains the parts and where they go, which can be found below or in the thumbnails above.

I have not had a chance to print this yet, and I probably won't until after the movie so in the spirit of good will and fellow Star Wars fans, here are the parts. If there are any issues at all please let me know and I'll correct them ASAP but I've been pretty thorough on this one so I'm hoping it should be smooth sailing.

I was going to add the extra's, but someone uploaded one that works pretty well, just heat up and shape to your helmet.



Print Settings

Rafts: Doesn't Matter

Supports: Yes

Resolution: 0.3 is Ok as its going to be sanded

Infill: Very low, if not none. Use 2-3 walls/shells.


All Parts were designed to be printed on a Makerbot Replicator / Flashforge size machine, ie 22cmx14x15, if you need something cut into smaller pieces, please message me.

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Kiri:Moto is an integrated cloud-based slicer and tool-path generator for 3D Printing, CAM / CNC and Laser cutting. *** 3D printing mode provides model slicing and GCode output using built-in...

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When I go to print PART 4 updated (As it prints upside down) it prints to 22% just above the eyebrow and extrudes no more. Tried Part 4 standard and same result. I'm only a novice but everything else Ive printed has completed no problems. Previous helmet parts are fantastic. Any ideas Thanks

download the file again, thingiverse is corrupting downloads alot lately.

Just an FYI, as I'll sort my own problems out. Having an issue with PART_4_Updated. It comes out with a slight twist to the center (nose) plane. Using Cura slicer and an Ares printer. Everything else is coming out beautifully. I'll try a different slicer. Looking at the mesh, there some oddities to the end plane on that piece which may be confusing the slicer (?). Thanks this the model extremely well done.

Can anyone tell my which part is the largest so I can scale everything accordingly to my print bed. thanks.

Stupid questions... How do you create the eye lenses? I'm just over halfway finished printing the pieces, (ran out of black filament, had to order more), and can not remember where I seen how to make the lenses.

I'm also printing with PLA and was going to use "Gorilla" super glue to assemble the pieces. Many other prints fall apart when I used super glue. Is there a trick anybody uses to keep your props from breaking due to minor impact?

Thanks in advance for the reply(ies).

Mar 2, 2016 - Modified Mar 2, 2016
Geoffro - in reply to neckbreaker

I used a silvery black anti static bag(those ones electronic parts come in) and cut shapes for the eyes, but they are not as rigid as id like.

As for glue, i know others use acetone, I use 2 part epoxy glue, cheapest I can find.

The reason for epoxy..
When the 2 parts mix they cause s chemical reaction, which creates alot of heat.. Enough heat to open up cracks in the PLA and sink in.. It Mars for an incredibly strong bond.

It also doesn't dry instantly, allowing you to position a part without it sticking straight away.

Thanks for the advice Geoffro. I totally messed up this helmet. Once I get around to touch ups and clear coat I'll gladly post pictures and advice on where I went wrong.

After lots of surfing, I found a website that sells all sorts of accessories including material for eyes and a rubber gasket for the neck. If i had only known those anti static bags would be of use during my time in the Navy, i'd have saved every single bag those circuit boards came in!

Thanks again for the design and I look forward to reprinting this again and other of your designs (rancor pen holder!!)

What is part 22 for, if it's not the eyes?

Any reason you chose PLA over ABS? I'm halfway through an ABS print.

Could you do a clone trooper helmet.

Feb 14, 2016 - Modified Feb 15, 2016

Nice helmet.
Build these helmet vents http://www.thingiverse.com/thing:1342259 and glued them on the helmet.
Gives more details to the helmet.

Storm Trooper helmet vent First Order
by KeBeiL

Working on finishing mine up. Made it on a Monoprice Maker Architect ($300 model). Took 27 hours to print all the pieces. It's looking great! Keep up the awesome work! Anyway I can donate to you for your time?

Could you do a Boba Fett helmet?

Yeah, I am hoping to finish Darth completely today, we'll see how I go, Boba would not take long! very easy helmet to make.

Halfway through my first print, thanks for the model!!

Would you be willing to share a basic model for a helmet? I'm a noob with designing but think it'd be fun to play.


This looks like such an awesome print cant wait to try making this and the other trooper helmet. Thanks for taking the time to section the design into manageable components.

Could you do a version with Captain Phasma's extra details?

This is amazing. Now we need someone with your skills to put out some Vader helmet and chest plate STLs :-]

I've completed the Scout and storm trooper armour and the Darth Vader helmet, with removable top head piece etc, like the movie. All I need to do now is find a way to stop procoprint3D immediately taking the models from here and selling them on his website. Until then, i'm reluctant to release any more models. :/ currently fighting a 1 man battle and the guys an asshole.

Feb 22, 2016 - Modified Feb 22, 2016
JIPSTERR - in reply to Geoffro

Looking forwards to the Storm Trooper armor upload!!! Was the Vader Helmet and removable top head piece a bust model or wearable? This is a new father to twins (Boy/Girl) asking :-)

I would love to get a copy of your redesigned storm trooper helmet, even if I have to pay. I recently finished the finer details of my large printer build and now I'm dying to print out a trooper helmet from TFA. How screen-accurate is the new one btw?

Damn you procoprint3D! Ruining it for those of us who truly take Open Source to heart. You're right, he's an asshole. I'm not going to beg or put my email in here as I could be anyone and it would cause everyone to start doing the same thing. Fight the good fight my friend, and keep those kick ass skills up!


I've printed lost of different part by now but they do not fit....
I'm printing them all with the same setting but something seems not right.
Any suggestions?

Not sure sorry mate, 11 people managed to put the pieces together so far

I've printed all the parts now, what would be the best glue for it?

If you're using ABS, acetone is usually used to bond ABS to ABS. There's bit of a learning curve, too much and it'll melt badly, too little and it might not bond at all. There's other tricks and things to use, but that's just what I do.

What is the minimum printbed size for this?

I shall call him Tr-8r

...Watching FN-2187 betray the First Order...

Hello Geoffro
Really like this project!
Can you tell which is the internal size of this helmet

Is this possible to do on an M3D?

That's a great question. I want to know if it works on the micro too.

Love this. Printed all parts with no support apart from the pieces with the jaw vents. Will you be adding the cheek pieces?

Really? Even the dome parts? That has a 90 degree overhang

Yep, it loses about 30% thickness with a bit of 'spaghetti' on the under side but once it's padded and lined, who cares?

Can you cut part 3 and 4 in 2 to be printed with Da Vinci Jr. Thanks

Tendau - in reply to JFDE

you should be able to do it on a jr if you turn the pieces though i do agree that it would be nice =D

for part 5, my slicer sais that it isn't manifold/watertight and that it could have problems slicing. is that only me or is anyone else having that problem?

name of your slicer?

slic3r, I fixed the problem using netfabb so its fine now :D

Dec 21, 2015 - Modified Dec 21, 2015

For the remake you've mentioned, I would keep in mind the 501st specs for it. They also have some good high res photos of it.

The link http://www.501st.com/databank/TK_-_First_Order

Part3_updated has been giving me heck, I don't know if its something with the part, something with my printer, something with slicer or what (probably slicer or printer). Part 4 printed fine, as did most other parts but #3 has been skipping over on the y axis, it just starts printing to the side randomly, left 1/4 inch, right 3/4 inch, you get the picture, leaving me with a good start, dome few areas of good printed stuff but a bunch of white plastic that looks like I'm trying to print a spaghetti dish! I would laugh if it weren't my print!

if other parts print fine i think slicer make sshit. maybe u try another slicer i dont know.

ya i tried printing some other stuff too, it just randomly happens. i think it was because i had it printing at 300% speed and 150% extrusion rate so it was catching on the print where it crossed perimeters and made a protrusion, then caught on that. i THINK problem solved but its not just this, tried updating slicer, still did it probs printer but thx

This comment has been deleted.

I just have a couple questions...but first off, Awesome job on the model man, I love it. K, is this screen accurate (details and all), and has anyone made one and had it approved by the 501st? If so, I'm making one :)

good question, im making one as we speak, I'll see if it gets approved!

This one isn't screen accurate, it was basically 'close enough' at the time and it was more a "holy crap we need to get this out before the movie starts and if I keep tinkering it will never happen!"

I am adding all the new pieces soon, and they will be addon's, so anyone who printed the original mask won't need to print anything, but all it's missing is some detailing around under the eye and on top the head - and also some honeycomb type work on the jaws.

Really looking forward to seeing what you come up with.

Cant wait to see it...thanks for all your hard work!

How much filament was used to print this masterpiece?

Dec 23, 2015 - Modified Dec 23, 2015
tab328 - in reply to Forlani

i would have done it in less than a half kg with my settings, i had to reprint a few in silver since a few originals printed funny

how should i go about painting this

Dec 10, 2015 - Modified Dec 14, 2015

Slowly making my way through this, about 2 weeks worth of printing. I joined together 19/20 for one print. And joining together 1 & 2 for a print, with a major amount of supports. (1.05x scale) Without being joined, they curved a bit much, and would not glue together well. This is taking about 2.5 rolls of filament with heavy supporting.

Im gluing the PLA together with SciBond 16, and ill epoxy seal it to smooth it out, then sand it, paint it.

I plan on wearing it to pre-release movie event for work.

Major props on the design.

Hi Jarret.
Which parts have you used supports?

Pretty much all of them. Some pieces, I selected @ 30degrees, others at 42degrees ill support it.

Ow right, just find it odd.
I haven't had to use supports at all, apart from the top pieces, with massive overhangs.

This is awesome!, Printing until it's done!
Ignore the haters!
Was wondering if I could be cheeky and ask for the original files of the eye pieces?
I want to do a thin wall largish honey comb in them so I can apply a sheet of black tint over then to see through.
Unless you fancy doing it? ;)
Props to you for the Up.


I have a Makerbot Replicator Mini which has a printing size of 5 x 4 x 4 inches which is pretty small. Do you have smaller cuts to print on this. I know it will take a lot longer.


Geoffro - in reply to rsop

I don't have them pre-cut, but it would not be too hard to do. If I cut each piece in half, or all the ones that are larger than the mini bed size, then it shouldn't be all that many more pieces, mainly the eye pieces as they are fairly wide. If I have some time this weekend I'll see if I can get it done. I have alot of addons to upload too and some re-designed pieces. I just wanted to finish some of the other helmets I had going before going nuts on this one.

Hey mate, Oh I completely understand, if you can that would be amazing but I understand the limitation of that as well.

Thanks for the reply though :)

i think my printer is about 7-8 inches square so these SHOULD work, printing asap!

You are the best. I do not understand any negative comments to your work. I have printed the stormtrooper hemlet (the first one) AND I LOVE IT¡¡¡. Please continue with us.

Any way to have the pieces cut down to be less than 15 cm at the longest? Have a da Vinci Jr printer would like to try this.

Really want to print one of these but I'm still pretty new to this, can anyone recommend a good free slicing/resizing program for this?
i have a bigger head and a small printer (M3D - works pretty good but not a lot of area to work with) so I'm kinda stuck

If you have windows 8.1 or 10, 3d builder is a free app made by microsoft that allows you to cut STL files in half and export them seperately

that's not a bad idea for the full helmet model that's included in the pack.

I'm rolling a pretty big bay on a Taz5 but the entire helmet was going to take more hours than I can monitor a printer lol

shut the front door... really, I had loaded it up before but I am used to using other programs that I didnt really get into it, the fact you can do that is pretty cool! I will have to go back and have a closer look!

any recommendations for a Mac? or is this something i may be able to do with ZBrush?

Nov 10, 2015 - Modified Nov 10, 2015

What is the layer thickness of the model?

hi, a lil question, how did you measure it? cause 30 cm sounds really small for an adult, unless u are not measuring head diameter. thanks!

Awesome job!

My 8yo daughter wants me to print it in PINK!

What size head is this?
I will want to re-scale it for her...

Thanks, it's for an adult head, the outer diameter is 30cm at its widest point. Mrbaddely thinks scaling 105% is good for an adult, so I guess I would scale maybe to 75% for a child, I would measure her head diameter then use the full helmet model I supplied. The scale of the full helmet is identical to the pieces, so whatever you measure using the full helmet as a guide, you just apply that scale to the pieces before you print.

If i send you a model..that's very close to being accurate..do you think you can modify it?

its looking great..how hard would it be to raise the chin up to make it look more like the trailer version?

The helmet looks great fantastic work, Any chance of getting the model in one file?

Yes one file would be great. have print area of 15" diameter x feet tall

sure, give me an hour or so

Thank You.!

Oct 27, 2015 - Modified Oct 27, 2015

Will this print on a printer with a 270X200X170 print bed?

Yeah should be fine, no parts are that large.


Thanks. Need to start printing soon to be ready in time for Christmas ;)

Oct 27, 2015 - Modified Oct 27, 2015
Geoffro - in reply to Kanedias

ooerr. sorry.. I did a bulk upload, they must have failed, I'll fix it now, thanks. * Edit, all done