Tie Fighter Helmet Full Size

thingiverse

As with all these awesome PDO files online, I've been working on a simple way to turn really cool 3D helmets into wearable items. Using Windows 10 3D Builder, I split the item into eight separate STL file pieces using its built-in function. Then, I rotated them for optimal printing and minimal overhang. The shells are printed with four to six layers, while the infill is set at 10% to 20%. Afterward, all that remains is to dremel off the waste product and scrape out the infill, leaving a perfect outer shell. This can then be glued together for a precise helmet reproduction. I started this project today and have posted pictures of the first four pieces. Each piece requires approximately 500 grams of plastic, totaling just under four kilograms per helmet. Most of that is waste, which can be reused or turned into acetone slurry. Using homemade filament costs around $16.00 worth of plastic.