A helmet to print for your cosplay...or to gift to your life's greatest blunder, if you've got one ;)
This helmet is intended for cosplay, and is scaled to be wearable for somebody about 5 feet 6 inches (~168 cm) tall. You're likely going to need to scale it up if you're bigger than that (the mask will be tightest from the tip of your nose to the back of your head, so scale based on that measurement). If you just want a miniature version of the helmet, there's official merch line called Mask Collection (マスコレ) that I'd suggest checking out instead of printing this (they've released a new Kuuga Ultimate for it as of September 2017).
Feel free to print via 3dhubs/university printing services/etc. Print mass should be around 200 grams.
Sorry for the weird filenames. Here's what they all mean:
40cm is the entire helmet, not sliced into parts or anything. Use this if you want to cut the file into pieces yourself. All files other than 40cm are individual pieces of the helmet.
Eyeskuuga are the eyes. They are bucks, meaning that the intention is for you to vacuum form them. You don't need a fancy machine to do this: I literally just nailed some scrap wood together into a box, drilled holes in the top, sealed the seams with hot glue, and bam! cheap vacuum former. You can find more info about it online if needed. After putting them in, I used fursuit eye mesh to back them, so I could see through them while making the eyes opaque.
26resclaback is the back half of the helmet.
26rescaledtop is the top half of the front half of the helmet (in less confusing terms, the horns).
The last 3 files will depend on what your printer can handle. 26rescaledbottom is the entire front half of the helmet below the horns, but some printers aren't able to print it properly. If this is the case, print both 30bottomteeth and 30verybottom and glue them together; the two files combined are a perfect copy of 26rescaledbottom.
Print, filler agent (I like to use Bondo on the outside and fiberglass on the inside, but use proper respiratory protection; see below link), filler primer, paint.
For the eyes, I printed them out and used them as bucks for vacuum forming some cheap 5"x5" sheets of PETG I got off ebay, then dyed them with idye poly. The helmet is connected via rare earth neodymium magnets about half an inch in diameter on the inside.
Good guide for respiratory protection when using Bondo or fiberglass resin.
Modeled in Blender.
Used a UV sphere, scaled it in the x/y/z directions, and added a subdivision surface modifier to get the base shape. The mouth area and 'ears' were meshes separate from the base UV sphere with a subdivision surface modifier added. The horns used curves that got converted into mesh later. I used a curve to knife project into the base for the basic eye shape in order to make the eyes recessed into the helmet's side a little, then made a separate mesh for the eyes.
Used the bmesh boolean tool to clean it all up, then added a solidify modifier.