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Stormtrooper Armor (Not screen Accurate)

by Rinaldi94, published

Stormtrooper Armor (Not screen Accurate) by Rinaldi94 Oct 31, 2015
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3D Printed Stormtrooper Armor (not screen accurate). Feel free to tweak and improve these files. I printed the whole suit of armor for Halloween 2015. I scaled everything to fit me. I'm 5' 6" tall and weigh 150 pounds. I have had to do some trimming and adjustments to the printed parts to make them a little more comfortable to wear and more form fitting but they worked great for what I wanted. You will have to bondo them if you want them to be perfectly smooth. I put a thin layer of bondo on everything before painting to take out the print lines. The forearm and shin pieces needed a little more bondo to take out the angles on them. I'm very happy with how this turned out. I created some of the pieces and others are modified from files I found online used for pepakura (I would put up a link but I can't find them anymore). The helmet is from http://www.thingiverse.com/thing:391664

Print Settings


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I printed everything with ABS without supports or rafts. I did have a few prints fail but i restarted them and they printed fine. I have a Rostock max V2 from SeeMECNC so I had a big enough print area to print the thighs in one piece. The shoulder, arm and hand pieces i mirrored to print for both arms. The shoulder straps needed a lot of heat gun attention to tweak to the right position and shape.All Parts should have a flat side to position on the print bed. This is why the shin pieces are cut into two pieces. To scale makes sure you measre the x,y,z on your body parts to make the piece custom fit you. When printing the shin pieces make sure you make the bottom part large enough to fit your foot through (I messed this up on my first print). It took about 300 hours of print time to print all of the pieces including the helmet.


Add Some 3D Printed UV color change designs to my Storm Trooper Armor


After the parts printed I put a thin coating of acetone on them to melt the layers together better.Next I added some bondo to the prints and sanded them smooth so the print lines would not visible.

Thigh Adjustment

I had to adjust the top of the thighs. I did this by cutting up the back of the piece and overlapping the top a little bit and then pop riveted it in place. I also added some foam pieces inside the armor to make them have a tight fit.

Connecting Pieces

I connected the lower chest piece to the lower back piece using elastic. I also attached the shoulders to the shoulder strap with elastic at the top and I added a Velcro strap from the bottom of the shoulder to the inside of the bicep piece.

I added a file called Strap loop to attach on the inside of pieces to connect them with straps to keep them in place

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very nice work. printing a set of armor myself with a combination of parts from your design and the set uploaded by sn3850. Your forarm pieces are much closer to movie armor. Also your ab design i like very much. Thanks alot for sharing your hard work. Wanted to add that instead of using bondo to smooth out the forarm pieces as you mentioned, i used the smoothing feature of 3d builder to round out those lines.worked like a charm and the pieces require very little post sanding and filling. Anyways just a tip for any users downloading the parts. also for some reason i had to scale the formarm to 1.7 in order to fit which is a huge scaleup. im actually about the same size as you from what you mentioned so not sure if that was to be expected or if somehow the scale was messed up during my repairs of the parts. NO COMPLAINTS at all, just some things worth mentioned for others downloading these pieces. Love your overall work and is saving me a ton of time is putting together a set of my own. Ill will add more notes as i continue to print pieces if there is something worth mentioning about the process.

I printed the forearm and it has multiple errror/holes, wtf.

It's a work in progress and I don't have time to keep working on it. That's why I stated that the forearm and shin pieces needed a little extra work after they are printed.

Actually they need work before they are printed.

so work on them. These things are going to happen. You got these files for free and should show some appreciation. If you took the time to learn the process you would know that different slicers may find errors that othr software will print without complaining so you should run your parts through something like meshmixer(which is free) to look for and repair errors. it takes about 10 seconds flat for this process and helps ensure good prints. 3d printing and design is a finicky and somewhat complicated process. its up to you to ensure your parts are sound for printing. oh and the uploader mentioned quite clearly there was alot of work to make these files usuable for costuming. ...try harder.

I printed every file on here as is and did some bondo work on them to finish them. If you want it to print perfect without need for post processing feel free to remix it and upload a fixed file.

Are all the files the same scale for when you printed it? Im printing this for a buddy and he is a bit over 6 foot and around 170. What's the best way to measure for the upscale since some of the parts are rounded?

how do you get so pefect surface between the pieces? i fixed it together but with normal glue or model glue its not that good if i spray it with paint... you can still see the different parts were they are glued...

I used an epoxy made for plastics to glue them together and then I put a thin layer of bondo over the seams. After that I sanded the bondo smooth and painted it.

I'm not great at the design side like others on here, fanastic piece of kit, but I cant chop it up to fit my 200mm x 200mm bed, any chance of slicing it up to fit my bed?I'm sure there are others on here with the same problem :)
thanks in advance

Very nice, I hope to have the guts to size and make this one day for my dolls.

I wish though if you could design the breastplate with cups

Amazing work, thanks for posting this.

I've been trying to slice the forearm piece and it slices with a hole in the side. Any idea what could be causing this?

I think it just has a piece that is really thin (less than a mm) that the slicer doesn't see. If you open it in mesh mixer and run the repair tool it should fix it. I was in a hurry and never got around to fixing it. I just printed it and filled the hole with bondo.

How will it fit a person that is 170 cm (aprox 5'7") ?

It fits me good and I'm 5' 6" tall.

Awesome work!

How heavy is it to wear? I've made a few 3d printed helmets and then used bondo to smooth everything out. The end products always look pretty good but end up weighing a good bit. I would be concerned this would be uncomfortable to wear for longer periods of time.

It's not too bad. I ran a 5K in it and I wore it to see the force awakens and wasn't uncomfortable.

Could you make an elbow piece to go with the armor you have?

what is your area for print. and which print are for this print parts. i have zortrax and my print area is 20x20x18 is it enought or how is the best scale for print parts tell me your hıght (cm)?
help pls me too wnat to print this auickly in 20 days

My print area has a diameter of 28cm and a height of 35cm

I added a file called Strap Loop to attach on the inside of pieces to connect them with straps to keep them in place. I'm using them to connect the thigh pieces to the abb plate and to connect the abb plate and back plate over my shoulders to keep these pieces from sliding down.

I have motivation now - same height as you but was over 225lbs now down to 174. If I can get to 150 I am printing and wearing this armor!!! Don't want to hear 'Aren't you a little fat to be a Storm Trooper" again.

update, I am now 141 lbs . . . .and now ready to print!!

Good job! Have fun with it. I added some UV color change patterns to mine.

How much filament did it take to make ? Also how long was the overall printing time roughly ?

I think it took around 12 pounds of abs. It's a little hard to tell because I printed a few other things with white abs during the printing of the armor. Total print time was around 300 hours.

Hi. What infill percent did you use on this? Great work btw

I used 20% infill.