I recently bought an Xbox 360 Kinect before the Death Stranding trailer featuring Die-Hardman was released, and was inspired to make my own after 3D scanning my head. It's not 1:1 from the actual Die-Hardman mask, some artistic liberties were taken to fit my face. Looking at it now, there's some changes I'm going to make to make it more accurate, especially if you switch back and forth between my picture and the actual picture. I have a fairly large head and Germanic face so your experience my vary. I have included the blend files so you can improve upon it however you want, but make sure to multiply the mask size by 100 before printing.
There are no loops for straps or strings. Costume glue could easily affix it to my forehead, nose, and cheeks.
I'm marking it as a WIP. Future plans include printing in abs, smoothing with acetone, hydro graphic dipping it in a carbon fiber texture, then painting the cheeks and details for an accurate representation, and I'll post instructions and pictures for that.
Special thanks to the hard ops addon! It wasn't entirely necessary to use but made the booleans easier to visualize.
DieHardman.zip is just a zip file of the STL.
I printed it vertically with the jaw flat on the bed (not as shown). The infill and resolution aren't set in stone so do what's best for you.
PVA was used as a support but was dreadful to remove so it really doesn't matter what you use.
I accidentally printed without support once (it ran out right as the bottom jaw was finished) and really the only thing that was screwed up were the teeth, upper eye sockets, and the cheek bolts, so I'm guessing if you want to save some filament you can specify those areas in particular.
I used Reconstructme to scan my face with an Xbox 360 Kinect before modelling the mask over it. I sculpted the teeth on after subsurface modelling the face. You can pretty much derive my workflow from the blend file. I've separated some of the major and more customizable steps by the layers. The only thing I didn't include was the 3D scan of my face because that's a little personal!