Wearable Darth Vader Helmet (for Prusa i3 sized printers)!

thingiverse

Because this did not appear in any Thingiverse searches or listings, it has been reuploaded here: https://www.thingiverse.com/thing:4360228 It has taken a long time to complete this project, but I have finally finished. Let me begin by thanking Steen Winther. His model (https://grabcad.com/library/darth-vader-helmet-2) was the starting point for this remix. 14 months ago, I began this project and today it ends with me sharing this remix. I hope it will be useful for some of you guys. If you decide to print one, I would love to see your results. The model is divided into pieces that should fit most i3 style printers. Each part has alignment holes designed to help with the assembly process. Toothpicks are used to insert into these holes and line everything up before gluing. Keep in mind that if you resize the models, those probably won't fit, so find some small nails or something else rigid enough and suitable for the holes. If you want the option to wear the mask, don't forget to separate the back parts (FaceR00, FaceR10, FaceL00, FaceL10) from the rest. Use the alignment holes to ensure everything fits together, but do not glue those four parts to the others – only to each other. I hot-glued some velcro to the top and magnets on the sides to snap the mask together. For the lenses, you can either print them (if you only intend to display the helmet) or form the lenses using the buck models. I used Worbla Transparent Art dyed in Jacquard iDye Poly Red. This worked great, but unfortunately, I used too much heat when forming them over the bucks and ended up damaging the Worbla. I might redo them at some point, but for now, they will have to suffice. Also remember that PLA can deform easily under heat, so you may want to use ABS or PETG for the buck models instead. Oh yeah, there's also sanding involved – lots and lots of sanding... For a great result, probably more sanding than I did :). I did not paint the 'nose' silver/chrome because I don't like the way it looks, so now you know :). The helmet and mask only fit together if the mask is raised from the surface. To solve this issue, I designed a stand. You can find the stand here: https://www.thingiverse.com/thing:4358923