Took a model from the game and made it printer friendly. Working on the rest of the armor. These pieces are for a full sized adult, about 6 feet tall, maybe up to 6'4". The rest of the arm armor is nearly done but the scale is wrong and i haven't designed the peg slots yet. At this scale, these will fit on a makerbot/flashforge printer (about 8"x5.5"x6"). big_red_frog's helmet is linked here because it's beautifully done and there's no point inn me trying to undo that person's hard work. Not reinventing the wheel here- I just want to make a fully printable Halo armor set available for the public and I think I have a decent process in doing so. Suggestions on scaling, fasteners, etc are welcome as I am relatively new to this.
I would superglue 1/4" pegs (or rods cut to size) in, superglue the seams a tiny bit, and then use a wall plaster or putty to seal up any seams. Thin wooden dowels are very cheap and it's not worth 3d printing pegs that will crack and snap easily. I may design peg hole caps that could be 3D printed but those are minor at this point.
Let it all dry, sand it down, and paint over it for a great look without the pain and suffering of a true old school cosplayer.
Note: flip parts 2 and parts 3 upside down on the print bed to save material.