Apollo astronaut suit components that I designed for a fancy dress party.
Components were designed from historical photographs of the Apollo program space suits. Reference photographs used were from the Lunar Surface Journal.
The neck ring is the largest component at 30cm in diameter. This has been broken into 4 separate pieces to allow for printing on the majority of printers.
A high infill percentage is not required for these components. However, ensure that the number of top layers is increased (I used 5 top layers) to prevent sagging of the top layer due to the low infill percentage.
Allow yourself plenty of time when making this suit because the time required for printing and finishing the components is significant.
Smooth the surfaces using sand paper. Start with a coarse sandpaper of 80grit and progressively move up to higher grits. I focused on making sure the top surfaces had a smooth finish.
The four quarters of the neck ring need to be assembled together carefully. Ensure that the adjacent edges of the four segments remain parallel to each other when sanding. Once the four segments assemble together well, glue the segments together with superglue.
Use a clean cloth to remove all sanding dust from the parts. Apply a light coat of spray-paint primer that is suitable for use on plastics - Dulux Duramax plastic primer worked well for me.
Once the primer has dried, apply a red or blue spray paint to match the anodising used in the original Apollo space suits.
The metallic spray paint I used needed to be thoroughly shaken to ensure the metallic compound mixed correctly with the paint inside the can, otherwise the objects had a matte colour finish. A minimum of 3 coats of paint was required.
Metallic Sharpie pens were used for the silver and gold detail on the components.
For the mission patch, NASA emblem, name tag and American flag, these were printed on labels that were stuck to the suit. Dimensions of the mission patch and NASA emblem were found here.
As for the name tag font, searching forums found that the name tag font was most likely "Futura Condensed".
Once all the components were printed and painted, they were super glued to a white disposable coverall suit. When buying the coverall suit, there are different types. The cheaper coverall suits used for painting don't have an white opaque outside liner and will not look as good. Choose a coverall that would be used for chemical removal as these have an opaque white exterior.