Marshmello Helmet (for smaller printers)

thingiverse

Our first upload! My son wanted to be Marshmello for Halloween, but my Ender3 print area was too small to print the entire costume as one piece - all I could find on Thingiverse was a single unit. So I started from scratch and scaled it down to fit my son's head. Then I broke it up into three separate main pieces that can be printed and assembled independently. When you print the main three pieces, you'll need to print them upside down - supports for the eye and mouth openings will be necessary. I created some pins that help align the pieces during assembly. For the last joint, however, you can only use one bottom pin; I didn't realize this until it was time to assemble everything. Next, I designed eyes and a mouth slightly smaller than their respective openings so they slide in easily and can be glued into place. When printing the eyes, I used 25% infill with one layer walls and no floor or ceiling. This allows you to see through them - 20% infill might have been even better, but it still works. Due to the design of the eyes, they had to be printed as flat as possible on supports, taking into account line of sight when orienting them in your slicer. The inner diameter is 235mm and the inner height is 212.5mm - a bit too short for my head, but it fit my 14-year-old perfectly. The outer dimensions are 250mm in diameter by 220mm tall, but since I cut it into thirds, it fits within a 160mm x 160mm print area. Each third took about a day to print.