Scout Trooper eye pieces (to mould perspex)

thingiverse

I find this method easiest for creating eyes for all helmets I've done. These have a lot of extra plastic that doesn't need to be printed for molding the eye perspex so I use mesh mixer to roughly chop them. You will need: PLA/ABS/PETG/whatever your filament flavor is Perspex A rotary tool An oven Some aluminum foil A baking tray A large spoon Some hand protection (a tea towel) A lifting device (screwdriver) Print the eye pieces in the lowest quality that will come out of your nozzle and highest speed your printer can handle. Quality isn't an issue here as you only need the rough shape of the eye opening. You don't even need to fully print these pieces, only enough to get the shape. Glue the pieces together; I used superglue, use whatever works for you. Cut some perspex with a rotary tool to the rough size of the mold you just made. Line a baking tray with aluminum foil and place the perspex on the tray. Bake in the oven for 5-10 minutes at 150c. Lift the corner of the perspex after 5 minutes (with your lifting device, not your fingers) to check if the perspex is malleable. Now, with some appropriate hand protection, pick up the perspex and place it in the mold as best you can. Take your spoon and press the perspex into the mold until it firms up. I found using water to cool it made it warp so I don't advise that. Just put it to one side and let it cool down naturally. If you make a mistake, just put the perspex back in the oven until malleable and try again. I chopped the middle section out of mine so my nose has somewhere to go. I used some tape to protect my nose from the sharp perspex. Hot glue the perspex into your helmet. If you want a slightly better mouth piece, see here: https://www.thingiverse.com/thing:2572915 Update: Chopped them back even further and cleaned up the edges.