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Full Scale Stormtrooper Helmet (wearable)

by Geoffro, published

Full Scale Stormtrooper Helmet (wearable) by Geoffro Jul 11, 2014

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Summary

The print in the cover image is from one of MrBaddeleys awesome finished helmets. Thank you for allowing me to use your photo.
**** Have uploaded the full mask ask requested. The accessories and eye pieces will still need to be printed seperately.
46+ full masks posted, nearly 30,000 downloads! wow, thanks guys!

*I want to take a minute to thank everyone who has printed this and posted photos, I can only imagine the work that went into them all. This is not a 5 minute print, it takes patience, alot of plastic and alot of post finishing - BUT it is high poly, so you will only be sanding away print lines, not trying to smooth out polygons the old fashioned way...

(Size is in the second image for head entry, over all the dimensions are about 33cm wide/high give or take a cm.)
This will take a fair few hours to print. I learned from my previous lessons with the Imperial Guard mask and hopefully improved the ease in printing a full scale helmet. I have cut it down to 16 parts for this helmet + accessories, but they are small and shouldn't take long to print. I have narrowed the wall cavity down, so each part is faster to print and requires less plastic. All parts are plated for you already. you might find a better orientation, I just placed them as I intend to print them. I have added eye comforters to line with padding like a real helmet and also seperate glass, but to be honest I intend to recycle some old sunglasses for my lenses. which will go ontop of the eye conforters with some padding around them. I am waiting on more plastic, I ran out :/ so come next week I can start printing this bad boy. I have left this open for remixing, I hope people print it, heck, I hope they print thousands of them.. so if we can improve parts, or you have a suggestion please comment, and we'll make this the best home made stormtrooper helmet available.
https://www.youtube.com/watch?v=siLuE0JJUwo

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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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KiriMoto Thing App
Jun 19, 2016 - Modified Jun 19, 2016

How much plastic/hours of printing are required per print ?
Thanks
Great design by the way
Oh and also how would this print on a Wanhao i3 V2 printer?

I don't know the size of the Wanhao, but it took ~1.3 kg for me. I used meshmixer to cut down on support material needed. **TUNING SUPPORTS IS KEY! YOU DON'T NEED AS MUCH PLASTIC THEN***
Speaking of time. Meshmixer cuts many parts from what would be 19 hours down to 11.
I didn't measure how much time it took total. I just set them to print when i didn't need anything else.

I have a build area of 10 x 10 x 10 and wanted to do a custom fitted smaller version for my 5 year old. I thought that would be cool. So my question is can I just print the full version instead of resizing each part?

I would do an overhang test and calibrate support first. You want a clean break away support. If you scale it down the whole model, be sure the INNER diameter is bigger than you 5 yr old's head. after your supports are calibrated nicely, you have good layer adhesion, and have proper dimensions. Print!

As I advance printing it, i have a suggestion, why don't you separate all "black" parts to be printed away?, like the mics one, whouldn't it be good to print the "mouth" black area, the stripes under the nose and the "vents" close to the eyes?, also the black line over the eyes.

Don't know if it would take too much time, or it can complicate a lot the printing split parts, but should be really better for "pro" results (I guess).

If my 3D sculpt skill's wheren't ZERO, I would make a try with the Mouth area.

May 1, 2016 - Modified May 2, 2016
Geoffro - in reply to dazzlesp

It would take alot of time with the mask in it's current state because it has been subdivided so heavily, decimated and processed that you are no longer dealing with the original mesh, there are odd vertices all over the shop. It can be done yes, but honestly it would be faster for me to go back to the original mesh, cut out the black parts and go from there - but also as you can see, 50+ people have sorta done ok with it as is, and no ones had many issues with the separate black parts not being separate as anyone who prints this is painting and sanding it. It was not designed to be printed in all the separate colours of filament. No it's not perfect, and yes I should probably revise it but It's cool to see how innovative people are and how they work around those problems - they all have done a pretty outstanding job if you look through the makes. If only I could get a picture of everyone wearing theirs in one pic.. that would be awesome.

Yes, The models needs a lot of post-printing work, but done in separate parts, sometines will help. It's the same as building replica models, sometimes it's better to paint separated parts, and then join them together.

I'll try to make an "extra" to the black parts close to the eyes, to put over the helmet in a 2mm layer, but with my 3D skills...cant promise anything good :D

And I'll never complain about this model. Is the best One I'v found all over the internet, just wondering if it can be even better. :D

It could be better for sure, I just have so many projects going at one time it takes a lot to stop and focus on just one model, I would prefer more quality over quantity.

New one trying to print one. Right Now printing parts 5&6.

Curious thing I'v noticed, Parts 1&2 are in 90º different print position, any special reason? Just asking cose seems strange , but both printed nice.

The design of the Helmet is just amazing. Printing at 90% original size, hope it fits.

It's up to you really how they are oriented for print, I just export them ensuring they are flat on the plate.

What is the maximum diameter head size that can fit in this helmet as is? Can it easily be scaled?

Large-headed person here.

I have a large head and it fits well. (It even has enough room for some foam)

do you have a captain rex phase 3 helmet?

Mar 27, 2016 - Modified Apr 13, 2016
Geoffro - in reply to rdieken

I don't do clone wars stuff sorry, Ep IV-EPVI mainly as any thing after that should be forgotten :p

I'm working on this print now. I'm about 2 hours away from finishing part 1 and I have to say, this is taking much longer than I thought it would. Part 1 alone will have taken about 24.5 hours to print, and I did it upside down to reduce the amount of supports needed! Is it taking this long for anyone else?

Another good way to cut down on support is to render supports with MeshMixer

Thanks @brandutchmen! How would I go about doing this?

Meshmixer or the overhang test?
Which slicer are you currently using?

It takes time, However do an overhang test: http://www.thingiverse.com/thing:58218
After that, see which angles come out well and adjust the software to not have supports on those angles.
Print time went from 20h to 7.5 hours for me (for part 1)

Overhang Test Print (Customizable)
by walter

Hello, Is it possible to print the helmet in 1 piece on a Lulzbot taz5 ?

Mar 1, 2016 - Modified Mar 1, 2016
Geoffro - in reply to Simonr08

Only if your head can fit inside a helmet that is printed within a build area of 290mm x 275mm x 250mm.

How big's your head? :p

about 22cm large , 30cm height and 57m circumference. It is just but impsible to print in one part... wat printer do you use ? I'm looking for a TAZ 5 or an ultimaker 2+

I started printing in december, now i'm waiting for the glue to dry. Thanks for the great file.

1) Would a Makerbot Replicator 2 be big enough to print this helmet.
It states it's a 3D Printer with 2 extruders, LCD interface , heated build platform ,
1.75 mm filament / space 145 x 225 x 150 mm.

2) what sort of quality can I expect for this £300 3D printer.

many thanks, Panoramus

I have experiance with a rep 2.. They aren't the best printers for the price. What £300 printer are you thinking of?

Thanks! I am 6 parts into this print and I have a little lifting/warping but ill fix it during the putty/sanding stage.

I have been able to successfully print part 1 and 2 on my Da Vinci 1.0A with the E3D v6 extruder without needing support for the entire top part. You will need a little support tower at the very top tip where it tries to bridge Y to X but this has shaved off about 4-4.5 hrs from each part.

So awesome. Thank you! :]

This is awesome! I only have a print bed of 10 x 10 x 10cm.

Do you have any files for that size available?

What printer do you have?

PrintrBot Simple Metal

That has 150mm by 150mm by 150mm

This is a GREAT model and thank you for sharing it!

Has anyone successfully printed this on a Robo 3D R1? If so, I'm curious as to what your support settings were. I took the advice of an earlier post and used Meshmix to calculate supports (started with Part 1). Meshmix made this cool little tree-like support, but I had to cancel the print about 30% into it because the tree support failed, i.e. Robo 3D was trying to print it, but it ended up as strings between the support and the actual model. I wanted to save filament by using Meshmix as suggested, but maybe I'm doing something wrong. BTW, I'm using PLA in 0.2mm layers, two shells, 10% infill (hex), and the Meshmix support.

I printed this on the Robo 3d r1...(Pics coming Soon)
I used meshmixer for some supports,
however you should use this to calibrate supports http://www.thingiverse.com/thing:12925
I had to tweak some settings (like post diameter and base diameter) to get the tree like structure to come out right.

I also found Cura supports to use too much filament.. but then I lowered the support fill and changed the support angle to the maximum angle I can print.. Then Low cost cura supports! ;)

Bridge Torture Test
Jan 12, 2016 - Modified Jan 12, 2016
reilley - in reply to brandutchmen

AWESOME - thank you so much! Did you use Cura as your slicer when you tested and if so, what speed worked out best for you? I read a bit about it and see that other R1 users are lowering extruder temp to around 190-195. I usually run PLA between 210 and 220, depending on manufacturer.

I use Cura.. I print at 40mm/s outer shell. 50mm/s inner shell, 30 for bottom layer, and 60 for everything else.. I use 10% fill for supports.
Lower extruder temps are better for overhangs.. however that comes with less layer bonding. (split layers)

Sorry to hijack your comments @reilley & @brandutchman, I see your both on the R1 and using Cura I was wondering if you have seen the following size issues with parts? I am also using a Robo 3d R1 printing PLA at 8m nozzle with temps of 210 and 60 for the bed. Parts are loaded as is with no change to size, scale, or orientation. Specifically part 6 is longer than its alignment with part 4, both 7,8 are too small, 11 and 12 are too tall, and 10 is almost a half inch larger than 9 and the front parts 1,2.

Its probably total user error but I was curious if you guys had anything similar. if all else fails Ill just reprint if so what nozzle size are you two using? what filament ABS or PLA?

Thanks again for any info and apology for the hijack

Also just a shout out this is a great file, thank you @Geoffro! I plan on printing some of your Imperial as well!

Hey, no worries there! I just finished printing parts 1 & 2 today and they are not matching up very well. I have a feeling that Meshmix altered the scale of the original part, but I also noticed that parts 1 & 2 print on different seams. To test the theory that Meshmix screwed up the scale, I loaded parts 1 and 2 in MatterControl and yes, they are slightly different. I would think parts 1 & 2 would have exactly the same measurements but they do not. Must be the way they were sliced from the full helmet model.

I've been using Hatchbox ABS with a 0.4mm nozzle, printing at 235 degrees. I've had some layer separation issues and tried to kicking the heated bed up to 100 for Part 3 and that seemed to do the trick. I also shut fans down to 20% as well.

Thanks for the info! Thought it might be slicer thing but couldnt confirm. For this one i can see that some parts are accurate in relation to each other. As aresult i am gluing the remaining items todether, after they dry ill measure the voids left for the other parts and scale appropriately fingers crossed that works. Ill update here with pics if it does. Im sure to print another and that will be in ABS thanks agaian @reilley

That is way too hot.. I have printed with 205-220 degrees.. and the less bed temp is better
turning off fans causes splitting layers.

OK, I will try that tonight and see how it goes. I'm using ABS, so do you think 235 is too hot for that?

ohh. then use 235ish and 80 for bed.. and do some calibration prints to find the best configuration
Also.. Make sure there aren't wind drafts nearby.. they are bad!

Yeah, I do have a bit of an environmental problem. My workshop is down in my unheated basement and even though I'm in Atlanta, it's pretty cold here right now so I'm sure my printer is struggling to keep warm in all the right places. That darn print bed doesn't heat up exactly in the printed square either, as I recently found out. I'm thinking about buying Mike Kelly's acrylic enclosure to seal the freshness in, so to speak.

His enclosure is pretty expensive...

I use a 0.4 mm Nozzle.. Are your motor steps calibrated?

Feb 13, 2016 - Modified Feb 13, 2016
Truerobotech - in reply to brandutchmen

@brandutchman & @reilley It appears to be slicer related, I opened the stls in 123d and took down the sizes. When opening in Cura they had lost a number of MM in almost all directions. I think this combined with me changing orientations may have exacerbated the shrinkage. I have since resized and currently reprinting parts 7 & 8 if the alignment and sizing is correct I will be able to do the ear panels and it will be on to bondo and clean up. Future thinking next print Ill open each file and piece together in one large 123d file then copy down all sizes and make sure of them when loaded to the slicer. However before that next print Ill be doing a well run calibration of stepper motors and nozzle output. Ill post pics as it goes, hope you guys progress is going well.

ok! Hope to see that fixed!

@brandutchman pretty sure they are not ill do calbration and see just how far off they may be.

if that is 9 1/2 inchs across the head!mine is only 7 to 7 1/2 it is way to big for my head. i have a 22 inch head if i measure around my forehead. so how would i scale it to fit me...i am a novice..

You must have measured perimeter..

i suggest stop giving geoffro crap and buy you guys your own 3D printer so you can print your own stuff

Well said

did you make or buy the decals on the helmet, if you did buy them where did you get them from?

This comment has been deleted.

Impressive, most impressive....

This guy is making a shame out of all Belgians and the community in general.
We're not all like him. Thx a lot for your contribution Geoffro, i'm going to try this one as soon as possible.
And BTW I'd rather die than pay for 100 euro for a piece of garbage.

Jan 5, 2016 - Modified Jan 5, 2016
Geoffro - in reply to bevdberg

Thank you, and I would never assume that his behaviour reflects on any other Belgiums. We are all our own person, regardless of where we come from.

Dec 18, 2015 - Modified Dec 18, 2015

Since when is your file helmet, it is Sketchup file with a different owner, you are a regular cheater and a liar, but the truth will out.

This is your one helmet
http://i1159.photobucket.com/albums/p627/Christopher_Z/a_zpsvyqj38w9.jpg
This is your second helmet
http://i1159.photobucket.com/albums/p627/Christopher_Z/ab_zpspzdxplhl.jpg
Both are stolen from Sketchup

Nice work selling my prints on your site, 100 euros for your crappy prints? i'll start offering the same service for less than half.

Dec 18, 2015 - Modified Dec 18, 2015
Geoffro - in reply to ProCoPrint3D

So you took my model, took some screenshots of it and posted it and said it was from sketchup? you have gone beyond the realms of fantasy here, and I am seriously concerned for your mental health. In fact, I think it's dangerous even talking to you.

I just looked at his website,. All stolen models and he is trying to sell them for a lot! Wow what an asshole

Dec 18, 2015 - Modified Dec 18, 2015
Geoffro - in reply to brandutchmen

Sad isnt it :( you should see the mental messages from him - the guy is a real piece of work. He is trying to tell me now that his business has picked up even more because of his messages here. All I can say is if it's a war he wants. it's a war he'll get. He messed with the wrong Skippy.

Anyone who wants anything printed that he is selling on his page, I'll do it for 1/3 the price with free shipping. He want's 100 Euros ($150) for an unfinished printed mask, heck! I could do it for $50!

Hey everyone, for the real reason behind Procoprince's anger.. he's angry you are printing your own helmets out and not buying them off him! lol http://www.procoprint3d.com/#!star-wars/c1lqe

I can't keep up with you modifying and deleting your messages to suit your argument.
I don't have a gold coin to pass over your bridge sorry mr Troll.

This helmet is a copy of my but smooth. http://www.thingiverse.com/thing:325431
Here you can see perfectly, "how it is made"
http://i1159.photobucket.com/albums/p627/Christopher_Z/ab_zpspzdxplhl.jpg

And here is improved copy of the same Chelm only cut and hollow inside and more correction
http://www.thingiverse.com/thing:391664

Both helmets is a copy of SketchUp https://3dwarehouse.sketchup.com/model.html?id=57ffd28975abba38480514d7f2edc0a3
My version is also a copy of the same Chelm but I do not write with is my only version 1 of the revised angle for adhesion.

Stormtrooper Helm
Full Scale Stormtrooper Helmet (wearable)
by Geoffro

There are HUGE Quality differences... There is a reason more people have made this helmet

There is no difference it is only smoothed copy of one helmet for about an hour in response to the judgment, I might add original helmet made from the game Star Wars Battlefront
Compare yourself all the three versions and the versions of SketchUp
http://www.thingiverse.com/thing:325431
http://www.thingiverse.com/thing:362947
http://www.thingiverse.com/thing:391664
https://3dwarehouse.sketchup.com/model.html?id=57ffd28975abba38480514d7f2edc0a3

Colleague Geoffro knows where from it is the helmet because it copied and smoothed like most of his work, all you can find on other sites like SketchUp.

Stormtrooper Helm
StormTrooper Resculpt
by Geoffro
Full Scale Stormtrooper Helmet (wearable)
by Geoffro
Dec 18, 2015 - Modified Dec 18, 2015
Geoffro - in reply to ProCoPrint3D

I noticed you removed all the stolen designs from your page before you posted that, very sneaky. The simple fact is your helmet is NOT YOUR HELMET. You are whinging and whining about a model that was not even yours in the first place!. All you are doing is letting us all know how much of a ***** you are.

Dec 18, 2015 - Modified Dec 18, 2015
ProCoPrint3D - in reply to Geoffro

If so write that I deleted a lot of my item is to say that you were a big visitor to my Thingewerse and I saw you copied a lot of things
The fact is that your helmet is also not yours !!!! And you are a regular thief and do not say that someone is an idiot if you yourself are an idiot and it proved
Too many similarities with the helmet of course also with Sketchup and the same author.
http://i1159.photobucket.com/albums/p627/Christopher_Z/a_zpsvyqj38w9.jpg

He is offering the model for free and did a knock out job getting it ready for everyone to enjoy, while you are charging hellashish amounts of money for the same model. To you it's all about money, to him, it's about fun and bringing enjoyment to the hobby.

True that Man!

LOL so you admit you deleted all the stolen designs from your page before you came over here and started accusing me of stealing your model - all except for the one you are accusing me of?

You sir, have a few kangaroos running around loose in the top paddock I think.

You didn't even read any descriptions of any of my models did you? any time an original mesh is not mine, I clearly state the author If I know who it is.

I really don't know what you expected? you came here and commented, I left you alone months ago when you stopped stealing my makes and re-uploading them as your own - I thought that was the end of you, but sadly here I am again dealing with the same immature crap you were pulling before.

Now, I will ask you politely to leave or we will get the mods involved, your choice.

HAHAHAH
You know what you're funny you say that someone steals a model, and you yourself are a thief you write that you made a model of the game, then that I do not know where it is, and you know perfectly well that you downloaded from someone else, you change only the descriptions of how you around ass hot it got.
Never in your life have not done their model because they do not have a clue how to do it, you can just copy, connect, and smooth.
I am an engineer and a designer and my projects I sell because it is hard work and what it was or not, my Thingewerse, it is only processing but long ago I deleted just because of people like you every copy and write that it is their great work.
Tap in your head because you're a cheater man .

I think you've missed your meds today. I'm laughing at your "hard work" comment. At least I make an effort, you just upload other people's models without any work whatsoever. You're a flake.

Hey Copywriter I think that you have forgotten about drugs has long time ago.

It dosen't matter! You posted it as creative commons!

Dude. Just let it go. so what if he stole crap. that's the way of business. Its dirty and sneaky. that's life. Stop being a 11 year old.

i didn't steal jack shit off him. Take a dog, both of you share an end.

It wasn't toward you you dumb ass. the ass hole who is stealing it. lol tho

You published your model under CREATIVE COMMONS
You CANNOT ATTACK Geoffro for this.
(Technically you stole this design from DISNEY and the STAR WARS Franchise)

besides, he isn't making any money from it. Why are you mad?
Why would you attack a fellow engineer who is helping the advancement of 3d printing?

I attack since early in the descriptions was that this is his job, now it has changed but still manages a hustla, and is a regular asshole

Yes, you attack, attack and attack. You attack someone who gives people something free to print while at the same time angry because the model you stole and tried to sell on your website is not getting many sales - why? because its available here for free.

Who is the asshole again?

OMG you are stealing models from here and selling them on your website?? you piece of shite.

As you would be a little more intelligent then you would know that I do not sell models only printing service

As of 5 minutes ago, I noticed you just removed your model sale section and replaced it with one model.

If I catch you selling my models on your site again I will make a personal trip to Belgium and show you how Aussies treat such scum and villainy.

Stop dim that I delete something, you have no more arguments, but it can and maybe you already looked receives liar. Come welcome address you know will show you how the Belgians copy sucked such assholes like you. just remember that I am not of belgium, I'm just live and may you have been surprised. Ps.I'll pick them all and I will leave on my website

Such lovely language, I can see that you are a 'professional' designer....

I don't really care what your nationality is, it doesn't deter from the fact you are openly admitting selling other peoples models on your site, and now you have just threatened me in full view of everyone that you will now take ALL my models and sell them on your site.

You have removed MOST offending material from your site but you couldn't get to it all quick enough before people saw it and now you are angry that I exposed your little scam - which if you had just left me alone you wouldn't have had such a negative impact on your business.

One has to wonder why we bother uploading things here when people like you exist.

You have now been reported for profanity and with any luck will be blocked from commenting on my makes. Good day, asshat,

I 100% agree with you bro. Its just some dumb ass creating up shit because the Star War's movie just came out. I love you design. if only I can print it on my printer. LOL. Anyway your model has been up for like a year now so this weird guy is trying to steal your shit. I'd give a good lesson. Enjoy the Movie!!!!

Stop dim Copywriter about the fact that I delete files from my side I'm not a cheater like you and that officially threatened me first. Talk to yourself because you become so. You change the text descriptions of your files as I was writing it's not yours. You're just a crook and so much you can do, Copywriter.

You're an A class nutcase mate, you really are.

I notice the storm trooper helmet on your website for sale is mine and not your low res one, class act mate.

100 euro's for your dodgy prints? why? I urge people to print their own out - for the record I'll print anything he will for 1/2 the price.

Dec 18, 2015 - Modified Dec 18, 2015
ProCoPrint3D - in reply to Geoffro

As for me, you can even print for free. None of these helmets on my website is not yours.

True that!

Very nice copy of my Chelm

Dec 17, 2015 - Modified Dec 17, 2015
Geoffro - in reply to ProCoPrint3D

Your helmet? you mean the one you downloaded off the sketchup warehouse and uploaded to here and called it yours? unlike mine that is actually a resculpt of my own model that I said was originally from a low res model that wasn't mine? you're an A+ idiot. The helmet you uploaded was made by Pataplof, who is Spanish - last time I checked you are Belg.

I have my helmet had set a few months earlier than you, you idiot downloaded smooth out and say that this is your work. Can you tell me where is the helmet in your collection, it is the same smoothed copy of my Chelm. http://www.thingiverse.com/thing:362947
Even setting angle meters is the same so who's the bigger idiot?
Most of your projects is to copy and reworked with SketchUp or other sites so do not make yourself such a big deal because you have dealing with a novice.

StormTrooper Resculpt
by Geoffro
This comment has been deleted.

Of course, talk to yourself, you have copied from Sketchup and smoothed so you're the same thief, https://3dwarehouse.sketchup.com/model.html?id=57ffd28975abba38480514d7f2edc0a3

omg... you just busted yourself. LOOK AT THE GUYS NAME... now, look at my first reply to you.

I'm friggin cracking up right now, this is gold.

So I did not write that this is my whole work, I wrote that this is version 1 and revised by an angle of 13 degrees, showed also, how do you download versions 3

Look, I really don't have the capacity right now to decipher your rantings, I've just had way too many Scotch's.

This comment has been deleted.

Very immature, your model isn't even close to this quality wise. Geoffro is right

This comment has been deleted.

looks good, I'm gonna have to print this after the ep VII one

Hey, on the pic there is written that the depth is 19cm, If the size of my head (from back to forehead) is 19.5, should i bother rescaling?

Congratulations! You have been featured as one of the Top Halloween models for the year! To see your model and other Halloween models search this in google and click on the first link: "3D Printing Ninja Top Halloween"

What fill density should I print this at? And Whats the best layer height?

Oct 31, 2015 - Modified Oct 31, 2015

I am finally putting everything together, I would like to thank Geoff for making this model and his hardwork! Great Job!
Printing each parts takes an ample amount of time, continuous monitoring and a couple of failed prints (my part). Took me 2 days to print the parts and have used 1kg and a half maybe of filament for these parts, normal settings using Slic3r. Fitting is great! I decided to scale it down to 90%. Painting will be done tomorrow... just in time for the Halloween!

Tips: I find it easier to print part 1,2,9,10, 15 and 16 by rotating them upside-down, it has lesser support (used brim/raft) compared to what it is laid out here.

Again, thanks Geoff! (Please make an armor/suit/armor too!) :)

How were you able to print everything in 2 days? I'm just finishing part 1 and it took over 24 hours with a .3mm layer height! I did it upside down like you suggested but I used full support with ReplicatorG. I'm still very new to 3D printing so I was wondering what I might be doing wrong or what is unnecessary.

I'm not able to generate the gcode from the stl file for part 2... any pointers?

I would download the file again, and still if that doesnt work for you possibly there is an error in the mesh that your program is picking up that everyone elses did not, or at least the 26 people who made helmets so far. Run it through netfabb and try again. I just sliced it in Makerware and also in ReplicatorG and it generated G code and X3G without an issue, so im afraid I can't help you.

Is it just me, or are part 13 and part 14 identical?

Look closer :) They are mirrored. Load 13 and 14 into your slicing program at the same time - you will see they are the same piece but mirrored.

Hey everyone, for some reason I am having difficulty slicing up part 11, it says there is an unexpected error. Any ideas what it could be?

Fixed it. If anyone else has the same issue, try running it through netfabb.

Could somenbody make a eyrie storm trooper suit

Assuming you meant entire, and I second this request!

Hello, could you tell me witch pieces are in black for printing in the right color

You are going to have to paint them yourself. If you just print it in white, you then sand it, put a coat of primer on it and the paint part of the piece black. Look at a picture of a Stormtrooper helmet on Google Images to see where you need to paint.

How would you piece these together and secure them so they don't fall apart?

I'm about 1/4 the way through this build but I've been using superglue so far which is working well.
Once assembled I'll fill in the seams between pieces with melted PLA where required to hopefully bond it a bit better too, then filler, sand and paint will all help the hold.

Hello, I really love this Stormtrooper helmet print and was wondering if you would like to try a sample of our 1.75mm PLA filament and see how it works out! Free filament and free shipping, (United States only) just contact me at [email protected] and I can get you set up!

What settings do people print at? Every time i try to print part 1 it gets most the way done then falls over.

I am using a Prusa i3 with heatbed. Tried with PLA and ABS

I am thinking maybe i need to print with larger layer heights. Any Suggestions?

JQE - in reply to JQE

Turns out it was my printer and my calibration. So i now have it printed, and love it. Work on the post processing and clean up, then i will be posting some pics.

You using supports? I'm printing at 0.3mm with PLA on my i3.

Try using mesh mixer. That will save filament on support material

Sep 25, 2015 - Modified Sep 25, 2015
JQE - in reply to kellogg76

Yeah i am. I will try again, see if i get better luck.. Been frustrating. What layer height do you use? 0.2mm ?

i see you said .3mm for layer height?
I will try and see what happens.

One thing i've done in the past if the supports don't seem to stick well is to add a drop of superglue where the support meets the painters tape just to make sure it sticks solidly and supports the part.

@IFritZI- I used about a spool and a half. you might need less, but I'm pretty sure it will go over one.

Has anybody needed to scale this down?

I really like this helmet, actually i like it a lot.. The only problem and the thing that makes me not wanna print this, is the amount of support..
If i study one of the parts in simplify3D it says it takes about 7 hours, thats the time with support..
However if i turn off support it says 2hours and 30 minutes.. That alot of hours put into support alone and i think thats a shame. Your work however is fantastic and i have tried myself to find another way to split this but i havent been able too!

Try using meshmixer, It strategically places supports to save both filament and time

Oct 30, 2015 - Modified Oct 30, 2015
GamerGorman20 - in reply to supernielsen

Do you use the dense support layers option?

You can take the support infill down to under 10% if you use 2+ dense support layers.

Basically right before the part starts printing on top of the thin support, it will start laying thick support perpendicular to the previous layers.

Jul 21, 2015 - Modified Jul 21, 2015

About how much filament will this take? More than a full 1Kg spool? Pretty keen to tackle it, just want to know how much filament to order.

Hold on, Can you see through the view plates?

If you print them with transparent filament ;) most people so far have chosen to use alternative shades.

which parts needed support?

I want one but don't have 3d printer is there any where I can buy one preferred in uk? If so how much ? Thanks

If you just want to print this go to 3D hubs.com and see if there are any 3d printers near you. It costs much less than buying a whole printer.

If you print with abs you can use acetone and a brush to weld parts together.

Is it possible to get it cut into more pieces so its printable and somewhat scalable on a printrbot simple metal? (150x150x150mm), at the moment i can get all but 3,4,15,16 on the build plate, but most of the larger parts i can fit wont be able to be scaled =[

also whats the best way to paint it? sand it, use a filler primer then an enamel spray??

The design look amazing btw, i cant wait to print it!!

I could do that sure, obviously a bit short of time over Xmas, but shortly after not a problem. I am doing the new storm trooper helmet too, will prob upload it all at the same time.

merry x-mas btw!!!

oh yeah, obviously no rush!! i have seen the IV helmet your doing! looks sick! how do you get into that kind of 3d design? I've only really had experience on solidworks at uni designing a gearbox and a robot (geometrical basic shapes). I've just started playing around with 123D but that just seems like a downgraded version of that!

AndyXD, I have printed all of these parts with a Printrbot Metal Simple, it has the same bed dimensions, the only thing I had to do was change the orientation to 45 degrees on some of the pieces to the them to print diagonally across the print bed. I am just setting up piece 16 to print now with no issues (aside from some support for parts 15 and 16.

i eventually finished the helmet!, i ended up cutting a few of the pieces in meshmixer to reduce the amount of support material that needed to be printed, all in all it was about 24 parts. i used a dremel with some filament in place of a tool bit and friction welded the pieces together.. hold surprisingly well as I've dropped it and nothing bad happened.

I know when i went to print some of the pieces, no matter what orientation i had it in, it didn't fit in cura. so that's why i ended up cutting it.

All in all its a sick bucket! cant wait for the new one to be put out so i can wear it to the opening of ep 7!!

What size noggin do you think is too big if I print this at 100%? Thanks in advance.

My head is a big larger than the ID of the helmet, how does it do with scaling?

Create a sphere in a 3D modelling program, make it the rough size of your head, then use that as a guide when rescaling the helmet, you need to make sure your head fits in of course.

supports needed ?

not many, I used the, for the eye pieces

Oct 26, 2015 - Modified Oct 26, 2015
Le_Ferreira - in reply to Geoffro

HI, thank you for sharing this helmet, the model is awesome and I can't wait to print it, I was wondering if you could suggest some printing settings to avoid using that much support.
Cheers

You don't need much support at all, most pieces can be printed without it. The eye sockets I would suggest it, but other than that most of it you can go without. Any looping or mess will happen internally anyway, so you won't see any missed steps from the outside. There is many pieces, all I can suggest without knowing your setup/printer etc is to try the most complicated looking part first! alot of the pieces are tall and quite thin and don't take long to print.

Oct 5, 2014 - Modified Oct 6, 2014

I was actually going to suggest to split parts 1-2, 9-10 in to two parts to reduce the amount of support material needed.. just a thought.

I'll hopefully start printing this up this week!

Ok, have had far too many requests for the full helmet or variations of it, I am uploading them now, might take some time as my upload speed is snails pace. I am uploading 3 versions. Full , half split and quarter split.

Great Work! I´d like to print the helmet in one piece (or splitted in 2 halfs) with my big printer, could you upload or link the file?

I am Printing as well! Cannot wait to wear it to the convention! I had a request Geoffro I tried emailing you but no luck. I was wondering if you could do a Turian Mask for me!

This is fantastic! I'm printing this now at 80%, I think it will then fit my 6 year old grand son. He and I are wondering if the entire body outfit has been modeled and out there somewhere to get.

Thank You Geoffro great work I'm working on printing this now. Is there a Bobba Fett helmet in the works?

thanks man, yeah Boba is about 20 percent done, not doing jango tho. Next mask is robocop which is done just print testing, and then Boba!

This comment has been deleted.

is there anyone out there who has a guide to putting this together? or pictures of doing so? or eventhe ability to tell me what to do?

you seriously didn't see the construction video , second image in the gallery?

I'm through printing, and the back and front i stuck together with E6000. ill be posting build shots as i go. thanks for the model mate, that shit is tiiight.

i seriously didnt realize that you just put the pieces together at the seams and they just morphed together with magic! thank you!
all sarcasm aside, i just meant like once i have all the pieces how can i put it together and make it look all nice?

Personally I used hot glue to hold it together. I am in the process of using a high build primer, bondo, and sandpaper to smooth it all out.

I too would like a one pies STL file of this so I can simply re size to fit for different head sizes.

Please. Ans thanks for your hard work!!!!! Looks great!

Amazing work once again.

Time to see what the Huxley can really do.

Can you supply an uncut model of this? I have a large build volume available and would like to print it as one piece.

hi there,
how can i split one part into two smaller ones?
thx for ur help

i use netfab cut tool then repair tool

Works great, THX alot

Hi your avatar looks like star wars bounty hunter head where did you get that?

its a boushh helmet i made out of Polystyrol some time ago, now i got a 3d printer... im trying to work with this medium.

Like I said absolutely amazing I have a dimension sst768 and a zcorp 450 these will be spectacular!

It's already been made and ready for upload, I actually made it about 2 weeks ago. I was just trying to gauge what sort of masks people wanted and also to make sure they are made correctly. I do not like posting models that I have not printed and tested first, but obviously a 16 part mask takes a long time and I know there are people with better printers and faster printers than me and could print it out in one hit even - that's why I release these before I have actually printed them, but I don't just upload them and say" Here go for it!" It's a long process. I have to slice every single piece and print preview it, with and without supports to make sure each one will print ok - among many other things. All that is needed for the scout helmet is a small animation to show the part numbers for construction, those videos take me around 30 mins to do, so it's not a big job. I'll have it uploaded tonight.

Hey still awaiting a response man TIA

I will try to find it, had a bit of a hard drive crash, 99% of things were backed up but still looking for a few odd ones.

Could not find this Scout mask you were speaking of can I have a direct link please?

I could not agree more never watched them but the movie gree was neat looking.

which version? I see 2 versions, one that looks more like a clone trooper and one that looks like a green standard stormtrooper.

What about commander gree! You rock at this stuff man!

I'm trying to steer away from the abomination that is Clone Wars.

fully agree... (even the new episodes I-III are not my favorites, the "originals" have more spirit IMO)
Thank you for sharing this !!!!

Wow. I am so building this on the X18 next week!

Kick..........ass.........thanks! ;)

I am sooooo going to make this next week!, can i ask, whats the size of the biggest part? My build area is 14cm x 14cm. Thanks

a couple of the parts are just over 14cm sorry, let me know what doesnt fit and ill cut it for you

Cool thank you

I'm half way through printing this and I think it's too big. I think the original ones were 30cm x 30cm.
No body else seems to have noticed? Am I wrong? The one I'm printing is huge.

Sounds like your slicing program might be increasing the scale? not sure sorry. I have seen this printed now more than 10 times and by default seems to be about the right size for most heads.

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