Black Series Stormtrooper helmet vents

thingiverse

These three pieces are made to replace the grey vent details on the Black Series Stormtrooper helmet to make it more accurate. These are for only the modern movie Stormtrooper "ROTK" props (Rogue One style Stormtroopers of the modern movies - this specific style of Stormtrooper armor is also used in The Mandalorian and Obi-Wan Kenobi series, not in the original trilogy style troopers). In these new Rogue One suits (that the Black Series helmet is based on), the grey details appear to be separate pieces, inset into holes through the white helmet, with a black backer plate behind. In the Black Series toy helmet, they are simply cast into the helmet, and painted black and grey. I designed the pieces in Adobe Illustrator, and then brought them into Blender and extruded them to 2mm thick. They are ideal to print on a resin printer, printed flat (up on 5mm supports worked well), and then heated and curved to fit. Print each piece twice, mirrored, to get the left and right side pieces, for a total of six pieces. I cut out the existing vents in the helmet with a Dremel just around the gray painted area (not cutting into the black painted border), and saved those parts, and used the cutouts as forms. I gently heated the resin pieces with a heat gun, one at a time, until pliable, and placed the heated resin piece on one of the cutouts as a form to get the perfect curve (or twist on the cheek vents). I then used needle files to widen the cutouts little by little until the new resin printed parts just fit. some of the curved edges may require light sanding to fit the shape even more perfectly.