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Death Trooper (AWT Trooper) Full Scale Helmet (Rogue One)

by Geoffro, published

Death Trooper (AWT Trooper) Full Scale Helmet (Rogue One) by Geoffro Nov 19, 2016

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Summary

I would love to give the suit away for free but as Benny from Total Recall would say "Hey man, I got 5 kids to feed.." Well, not 5 but 2 anyway :)

Rogue One - Death Trooper Full Scale Helmet.

Assembly instructions are in the image provided and the Dimensions.
14 Parts in Total, cut for a 22x14x15 build plate, full helmet is included its just taking a while to upload. Hopefully out in time for people to get theirs done before the new movie!

Supports Required on Parts
5,6,7,8,13,14

I figured this time I will be more liberal with supports (on the inside of parts..) and make less pieces to print. The thickness was increased on the bases to give them more stick so really no rafts should be needed if you are printing in PLA.

Seams are in easy to sand areas, either a large round area or flat. As usual I split the dome into 4 pieces as it seems to just work well that way.

If you like this helmet and want more, please support my Patreon page:
=====> https://www.patreon.com/Geoffro

Full suit is available
https://www.cgtrader.com/3d-print-models/art/scans-replicas/starwars-deathtrooper-3d-printable-costume

The details of it can be found above in the images, just scroll to the end - I have included the assembly instructions here so you can see all the parts you would be purchasing.
The Full suit also comes with a new mask that has a few more details on it that are more apparent now that we know more about the costume.

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Part 9 fail addendum. Could I just mirror Part 10 and use it in place of part 9?

Having a problem printing Part 9. Part 9 continues to fail at 97%. Not sure why. Part is 136mm tall. I rotated the part 90 degrees on the x axis so it is only 115MM tall. I think the overall part was approximately 136 by 115 by 87mm--this is just a guess as I'm not at home now. Even after rotating, the part failed again at 97%. I've printed parts up to about 160mm in the z axis with no problem, so I don't believe height is the issue. I also tried laying the part down and using supports, but still can't finish the print. Part 10 which is an inverted copy (x and y axis) of part 9 prints with no problem. Even part 7 printed with no problem, even if it took about 24hrs on my Anet A8. It appears there is something in the part 9 model that my printer doesn't like. It's almost as if the z-axis doesn't increment correctly and the printer is trying to place a layer where one already exists. As a result the part (even with a raft) gets pushed out of position or knocked over and the printer start laying down layers in mid air. The part will continue to 100%, but not correctly after 97%. I'm printing part 8 currently and hope it is complete (and good) when I get home from work. All other (14 minus 1) parts printed fine. If I can't get part 9 to complete, then I plan on using a piece of raft on the interior of the part and build the remainder of the part in putty.

Hey everyone! Hoping to get a quick response on this...
I'm somewhat new to 3D Printing (a few weeks) and was interested in this as a project. I used Cura to slice Part 1, and it sliced it fine, but when I click "Save to removable drive" (my micro sd), it says [Errno 22] Invalid Argument. Any idea what that means? I scaled it to 50% and it saved it fine but I want it to be wearable. I went down to 90% and it still did not save but I don't want to go lower than 90%, any ideas?
Thanks!

Actually I think if I use the Mac it's fine.

The same has happened with other parts, but the re breathers saved fine.

Part 8 is throwing an ambiguous error when I import it into Flashprint. All other files are ok except for this one. I can still work with it (in silico), but I haven't tried printing it. Any ideas on what could be the issue or whether I even need to worry about it?

Hey man, thanks for the files. I have some issues with the size of the pieces. What is the dimension of your build plate in milimiters? I have a Prusa I3 printer of 220x220x240 mm, but I am not sure if its build plate is big enough.

Hey man, thanks a lot for the upload. Im going to be using a smaller library 3d printer with a build plate of 9" x 5.9" x 5.5". Do you have any files with cuts designed for that size build plate?

anyone try to print the whole helmet as one peice? will it fit on a S4?

http://3dmag.org/en/market/item/3390/
Buggas, looks very much like this one ; (

A few quick questions, what do you recommend as a good sealer paint for these after we sand them down a little?
Also, what do you recommend to strengthen the build after its printed?

I'm sure there's better out there, but I can at least share what I use:

After using drywall spackle and sanding the seams, I currently use automotive gray filler primer.

If you're looking to strengthen the build, I have used in the past XTC-3D epoxy to smooth out the assembled parts. In hindsight, if I was just looking to strengthen something from the inside, I swear by Loctite 5-minute epoxy:

http://www.truevalue.com//catalog/product.jsp?productId=1154&parentCategoryId=3&categoryId=187&subCategoryId=1647&type=product&cid=gooshop&source=google_pla&9gtype=%7Bifsearch:search%7D%7Bifcontent:content%7D&9gkw=%7Bkeyword%7D&9gad=%7Bcreative%7D.1&9gpla=%7Bplacement%7D&ctcampaign=4680&ctkwd=%7Bproduct_id%7D&ctmatch=&ctcreative=%7BCreative%7D&ctplacement=108557-43411605579

Hope that helps.

I don't understand. my printer keeps slipping on the y axis at the exact same z height each print... I tightened the belt and print again and exact same results, 4 prints ruined. why?

i guess its not really a make but i didn't know how else to show my problem, I will delete it if that's a problem. https://www.thingiverse.com/make:322504

Death Trooper (AWT Trooper) Full Scale Helmet (Rogue One)

Hey Geoffro, i've really enjoyed building this helmet!

I've made a few adjustment and modifications to it (written on the "made" article).
I'll be glad to share this things if you agree.

Cheers!

Amazing work keep it up..loving the star wars helmets

Comments deleted.

New to 3D SW, and certainly not a CAD type person. So please be gentle!

I cannot slice part6 in slic3r (current 1.2.9). It just hangs with "processing triangulated mesh". I have tried multiple installations using the Fedora repositories for slic3r, and also the tar.gz download from slic3r.org. I do not have this problem on any other parts, but it is consistently on that part downloaded from this site.

I also ran it through blender (import/export of STL), and with that it did not hang, it was just missing several volumes after reimport to slic3r.

I went through the comments below, but did not see this mentioned. Since no one else is commenting about it, I have to conclude that the problem is on my end. So I was wondering if someone could tell me what slicer SW you are using, which is not slic3r?

It has taken a long time to get in to slic3r properly, so I must confess that swapping to another does not generate glee in my life.

Sounds like you're on Linux near-exclusively, but I'll at least tell you what I'm using just in case it helps:

I currently use Simplify3D near-100%. Before that, this print (for me) was done using Cura (available free from Ultimaker).

You may want to try running it through a repair on various services, just in case they fix something that's only affecting your setup, just to get you over the hump. Perhaps any of the online checkers, MeshLab, or NetFabb Basic (free)?

For the most part STLs should import into slicing programs with a couple clicks. If you're having to 'massage' the majority of them to get them to work in your installation that throws up a flag for me. I'll of course defer to anyone more knowledgeable in Linux on this topic. I use it only for unrelated work stuff.

Wow - that was quick, thanks Jimmy!

'massage' the majority of them

I don't but if I did I would concur. One of the set ups I tried was a pure default from slic3r, and I got the same result. That was when I decided to pipe up, as it was nothing I had done to my profile. The other parts have all sliced perfectly. I will take some time this evening and try Cura.

No problem and good luck. I just tried importing and slicing 6 on S3D. No hiccups, but I did notice it is one of the more complex pieces of the build. So it's not completely out of left field. If you're going to have software hiccup on you, it's those types of parts that'll do it.

I want to use this head for an action figure I'm making. How do I edit the size of the full helmet?

Almost all slicing software has scaling settings for whatever files you pull in

Do the parts just clip together?

Feb 23, 2017 - Modified Feb 23, 2017
JimmyTime - in reply to FinlayMaher

No. As with most large multi-part prints, how you join them is up to you. I use a combination of friction welding and CA glue.

For thinner edges with not much surface area to bond (which is MOST parts), I temporarily duct tape the outside together and line up the edges. Then, I put a small length of 3.00mm filament in my dremel. After you turn on the dremel you can treat it like you're welding the parts together on the inside edge. Takes some practice but for me it's my currently preferred way.

For some parts that actually have larger surface areas to glue, I will put CA glue on one part and spray the activator on the other. When you touch them together you have about HALF A SECOND to align them, and then they're stuck forever.

Good luck with your research. Please be aware putting prints like this takes some time and patience regardless of the technique you decide on

Nice models!
How can I print the fullhelmet stl? Only the very front touches the bed. Do I need to add supports or rotate the object?

You would need to have a slicer that automatically does it (most do) or you can manually place them.

Most of us either use the sliced pieces and join them together post-process, or re-slice to suit our needs.

Thanks for the reply.
I'm referring to the one stl file that is the complete helmet in one piece.
I'm guessing it needs supports all along the bottom, since it only touches the bed in the front when i load it into a slicer.
Just double checking in case there's a way to print it without supports.

Thanks

There's no magic to it - he's including the complete file as a courtesy in case you want to chop it up yourself.

ah, I see. Thanks again.

Hi here, you are a great designer who is very talented. My question is does this helmet have the indents on the back of the helmet, you have it on the version on GC trader, I don't really want the whole outfit so i was just wondering is this model has the indents in the back of the helmet.

To my knowledge this version is not as screen accurate as Geoff's one on CG since this one is free, and he made the indented one after this posting.

Also why don't you download this and check out the file yourself?! :)

Thank you, I was out and away from my computer so I couldn't check at that time. Will probably but the one in CG trader because I'm only gonna print this once coz of the filament cost. Again, thx

Geofffro your models are some of the best I've printed. I've downloaded and printed a couple of your files (T800 and the Batman Bust) the prints always come out nice. I've been doing some metal casting and I love using the batman bust for the castings. Just started printing the death trooper helmet. Can't wait to see it all printed out. I was going to do it in abs but had some warping issues so I decided to go back to pla.

The modeling side is where I'm trying to become more efficient. Currently I'm learning Fusion 360 with hopes of modeling my own helmets one day. At work I use Autocad Revit and have printed some of the furniture and casework pieces that I have modeled.

Anyway I just wanted to say great job. It takes a lot of time to create these models and we are lucky that you want to share. I definitely agree you should be featured.

Does anyone have an estimate for how much plastic this would take to print? I'd really like a tool that ingests a stack of .stl files and gives an estimate on how much filament you need to print it, doing it manually in a slicer one piece at a time is pretty slow.

Anyone know the best method for sticking all the parts together? I'd use super glue but I feel like the bond won't be strong enough. The sides the parts come together on are quite thin (understandably). Adhesive putty is really expensive and I don't know how the bond is with it. I mostly want the bond to be strong but if it can fill in the gaps between parts that'd be great too. Any ideas?

I use plastic welder epoxy. Its usually kinda cheap, but is really strong. Well worth the money!

Hi Geoffro,
Someone that had both the helmet and the CG Trader suit (the legit one) mentioned they were different. The full suit was more up to date with the movie. Is this intentional? At the moment moment I only want the helmet, but I would like it to be as accurate as possible.,

Hello! I sent a message on Cgtrader, I bought the full suit but would also like the original uncut files as I have a larger printer. Please and thanks!

So you are selling the design to it for 13 dollars? . Cuz i would love to buy it for that much , but i'd also like to make and sell after if i can ?

More than happy for people to sell printed suits, just not the files.

Hi Geoffro
Nice Build I have a 220 x 220 x 240 mm build plate will i be able to make this and how much filament will it take to make the helmet
Thanks Bob

approximately how much filament do you think this will take to print including support.

First of all, i want to say that im impressed :O with your designs @Geoffro.

I have downloaded the filed for this print, i dont own a printer by myself, but i have access to one in the factory where i work, and they told me that its ok to print this, not sure of the model, its a HP (i dont have it in front of me, so i cant say the model).

Then I had downloaded the FreeCAD and i see that i can open the files individually and the full helmet.
If that is not the correct soft to do it, can you recommend?
(design department has SolidWorks but im not a cad user)

Sorry for asking here if i shouldn't.

I see that the helmet is designed for a head 19cm from ear to ear or smaller :P, then i haven't measured my head yet, but if i have to resize, do i have to resize all the files or just the one with the full helmet?

Thanks a lot for the help and the design.....
:)

Thanks,
I recommend Blender to open and edit STL files, its free.

If you want to rescale to fit your head, rescale the FULL helmet, find out what % you scaled it to - then apply that scale to each part before you print.

So eg, if you had to shrink the full helmet to 96% to make it fit your body - you scale ALL pieces to 96%

Thanks a lot
:)

I download blender and check.
I understand that the result is a bit fragile, so it has to be a bit "bigger", right? then some foam can be added.
I just want the helmet

:)

Comments deleted.

How are you able to sell your 3D prints for so cheap? I am in the process of making a helmet and it is taking 5 hours per print. (thank you for the design :)

I would prefer to simply provide the files for free on everything to be honest, if not for scumbags like Do3D taking files form here and selling them on their site and screwing unsuspecting people over who sadly didn't check here first, everything would be free.

Really awesome stuff here! Started printing out the first few parts, and I had a question about 3, 4, 5, and 6. What is the inner ridge on those parts for? On parts 3 and 4, it's barely connected to the outer shell. Is that like a headband type thing, or an artifact of the modeling process? Thanks!

Comments deleted.

Hello! I think this is a great design and would love to print it, could you please make one that is split into smaller pieces? I have a Monoprice Mini and it only has a 110x110x110 build volume,
Thank You!

Windows has a program called 3D builder. it is awesome for repairing and for splitting up models. If you have windows look into using this free program.

Hi, yeah as Jim said really something you should have in your bag of tricks. I would love to spend 24/7 cutting up files for people - and if I did it for everyone that asked, I would literally be doing it 24/7..

I use blender to cut items manually because I don't have to rely on the constraints that meshmixer has and other programs that like to slice on set angles, like 0', 45, 90' etc. Blender allows me to "K" slice the object and then separate it and then seal the bottom.

I'd recommend downloading the free version of NetFabb or MeshMixer and learning how to split the parts yourself. This type of request comes up often across Thingiverse and it's best to learn how to do what you need yourself when it comes to splitting.

Just bought the full suit and at that AWESOME Christmas price special you have. You freaking rock dude! Now just need to get a hold of that wearable printable Darth Vader costume :-)

Awesome job Geoffro. Definitely supporting you with buying the full suit soon.

Hey Geoffro,

I'm up to part 6 so far and really excited. I tried to put them together roughly to see how it will look but the edges between combinations of part 3-4 and part 5-6 don't seem to flat enough to match. Big gap sits in between. What's the probable cause for this problem?

Thanx!

Comments deleted.
Comments deleted.

Interesting how defensive you become, just because of the link. Makes me wonder if your work is really worth the money.

Comments deleted.

Could I print this on a 8x9x10 build plate?

Comments deleted.

love it but can i get the chest,shoulder and the leg pieces. (if you even have released them)

Hi, you can purchase the full suit from here
https://www.cgtrader.com/3d-print-models/art/scans-replicas/starwars-deathtrooper-3d-printable-costume

I really want to release the full suit here for free, but within 5 minutes, Do3D or someone like that will take it, slap a $300 price tag on it and sell it. The only way I can combat them is sell suits for 1/3rd their price and stick it to them that way.

Big props to you man, Your models are some of the best out there. I personally really appreciate all that you've done. Ive got zero issues paying for models but your right some people are dishonest and charge wayy to much. Going to click buy now without a second thought, Keep up the good work and great prices!

To an untrained eye it looks pretty good but that first line "401's This may not be accurate enough for you, please look away in case you are offended :)" LOL

Tested have just uploaded an in depth video about the Death Trooper helmet https://www.youtube.com/watch?v=IiQykhvPG-Q

novos helmets are great, very expensive - but they are nice helmets. I guess it's "Do I want to spend $650 on an Anovos helmet pre-made?" or "Do I want to 3D print my own and finish it and be proud that I made a helmet for a fraction of that cost"

:)

Thank you for the reply, you've done a magnificent job with the model. Personally I'd print one rather than buying a pre-done helmet, I get the satisfaction of printing with the results being a wearable/display helmet. Just thought I'd put the Tested link here as it has the measurements (unfortunately in inches) to the official movie scale.

what infill and layer height did you use?

As soon as I've got my print bed leveled out properly, this is being made!

same

holy cow. This is awesome!

Uh, Part 7 & 8 need a lot of support....

"Supports Required on Parts
5,6,7,8,13,14"

Out of interest, roughly how long do we think this will take to print all the bits? :)

Looks stellar, can't wait to print! Thanks again for another great one!

Nov 21, 2016 - Modified Nov 21, 2016

I really wish Thingiverse would feature some of your work, I think they are a bit biased on featuring the same people over and over again sometimes. I guess they want to stay away from Star Wars related content and stick to hokey pokey stuff. No offense to others who have been featured.

Thanks mate, well yeah I'm sure there are alot of designers on here that would love their work featured. It's the people that join the same day, upload 1 make and get featured that gets me fired up, obviously friends in high places :)

awesome! any chance of the full armor?

not on here for free sorry, too many sites selling the files now. Can email me and purchase direct.

Amazing as always Geoffro!! - Just want to ask will you be adding sensor/range finder for the right left side of the helmet?

Is the first image a real photo or a rendering ?

It's a render

If you can get it to look like that once printed and prepped and painting ! it will b a thing of beauty. Nice model Good job dividing up for ease of print.

Damn it! I guess I'm going to have to pick up some more black filament. Yet again, great work Geoffro.

Nov 19, 2016 - Modified Nov 19, 2016

O my gosh, I am soooooooooooo drowning in the awesomeness level here. Great job!

Mate, that is cool. I really like this helmet and wanted one to add to my star wars collection , cheers Jace

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