Stormtrooper Armor (Not screen Accurate)

thingiverse

3D Printed Stormtrooper Armor - Not Screen Accurate. Make it Your Own. This armor was printed as a whole suit for Halloween 2015, scaled to fit this author's 5'6" frame and 150-pound build. A little trimming and adjustment made the parts comfortable to wear, form-fitting. If perfection is desired, bondo must be used to smooth out print lines. A thin layer was applied before painting. Forearm and shin pieces needed extra bondo for smoother angles. Printing took place with ABS without supports or rafts, resulting in a few failed prints but restarted with success. A Rostock Max V2 from SeeMECNC provided enough print area to print thighs in one piece. Shoulder, arm, and hand pieces were mirrored for both arms, requiring heat gun adjustments to achieve the right shape. Flat sides on all parts ensured proper positioning on the print bed, necessitating two-piece shin sections. Measuring body parts is crucial for a custom fit. Thigh prints should accommodate foot space, learned through first print mistakes. Approximately 300 hours of print time was spent creating this armor, including helmet pieces found at http://www.thingiverse.com/thing:391664. After printing, acetone was applied to bond layers together, then bondo was added for smooth finish and sanding for hidden lines. Top thighs were adjusted by cutting overlapping sections and securing with pop rivets. Foam pieces enhanced the tight fit within the armor. Strap attachments used elastic to connect lower chest and back pieces. Shoulder straps connected at top and bottom using elastic and Velcro, respectively. The 'Strap Loop' file was attached for internal connection purposes.