Kylo Ren Mask in 8 Parts

thingiverse

Big props to Jtm for the amazing original model! For this remix, I split the original mask into eight parts that fit perfectly on a small 3D printer with a 200mm x 200mm x 200mm build volume. The model is at its original size and fits my adult male very large head with some extra room for padding. I printed in PLA, then welded the parts together with a soldering iron, sanded them down, primed with filler primer, painted flat black, and added chrome areas using Testor's model paints. Check out this amazing video by Lethal Engineering that shows the process of making the mask: https://youtu.be/q4SUf6u8SyU Print Settings: Printer: Wanhao Duplicator i3 Rafts: No Supports: Yes Notes: I printed with skirts so the parts would stick to the bed better. Minimal support is needed, depending on your printer. But you don't need a huge amount of support for the big curved parts of the mask when printing in PLA with good cooling. Be sure to flip the parts around so a perfectly flat side is at the bottom of your print. I used this voice changer, hot-glued to the inside of the mask with the speaker on a necklace under my shirt. It worked great and really added a lot of polish to the costume: http://amzn.to/2fxu6ej Post-Printing: Taped everything up to make sure it was generally working. All the parts fit together perfectly, which wasn't a surprise at all. Plastic welding using a flat tip on this soldering iron worked surprisingly well, inside and out. Outside seams sanded down smoothly. Used Loctite putty to fill gaps. Anything would have worked well, even drywall patch stuff. Sanded it down after with an electric sander. At this point I should have added some of the details. Primed with filling primer, three coats. Painted flat black. Chrome was added using Testor's model paints. It took about thirty to forty minutes.