3D Printed Helmet: Follow The 10 Steps to Make Your Own!

So, are you wondering about making a 3D-printed helmet? With the blessings of technology, nothing is impossible for anyone. But you should know about the entire process properly before making a top-notch helmet.

My step-by-step guidelines can surely help you complete the task easily and precisely. So, today, I am here to show you 10 effective steps to create your own customized 3d printed helmet, ready to dive in?

What Is A 3D Printed Helmet?

3D Printed Helmet is a headgear that protects falls, sun, rain, or other elements. It allows you to customize your own headgear like never. The helmet is also very comfortable, stylish, and durable. Plus, the construction is polycarbonate, with a semi-flexible design and a reflective finish. 

Faceguards are also adjustable to allow full access to the mouth, nose, and eyes. You can customize the 3d printed cosplay helmet by yourself. It has the availability of different shapes and sizes. You can also include ventilation and adjustable face guards for better comfort on your head for better air circulation.

How Long Does it Take to 3D Print a Helmet?

A 3D printer can print a full helmet in about 15 to 50 hours, even if you use expensive materials such as titanium. The average time is 30 hours. Because depending on different types of things, time can vary. 

Factors such as the helmet size, material, design, and complexity will play an important role in determining this. There is so much demand for this 3D print helmet. Make sure what kind of helmet you want to make and how many helmets you want to make.

How to 3D Print a Helmet: Step-by-Step Guide to Follow

It’s surprisingly easy and comparably inexpensive to make your very own 3D printed objects. Take the best 3d printer for helmets before starting learning. Don’t miss these steps if you have ever wanted to create your helmet by yourself!

Step-1: Select a 3D Model of the Helmet

You can find 3D models and select one to print in several places online. A couple of websites contain different types of 3D printed models. You can make your own custom-sized helmet by modifying it to fit your head. 

Make sure to modify these helmets according to your preference and design, making them as unique as you like. As you will be modifying the helmet, you must ensure that any material used is compatible and suitable for this application. This includes nuts, bolts, washers, or other loose parts. 

Step-2: Scaling a Helmet to Fit Your Head

After downloading your model, you can open it up in your preferred 3D modeling software. The software has a feature you will want to use called “scale.” It lets you change the object’s size so that it fits more comfortably on your head. 

No worries if your helmet doesn’t fit right the first time around. You can always scale it down and print it out again at a smaller size until you get it just right.

Step-3: Splitting the Helmet

Before printing a 3D model, you need to prepare the S.T.L. file. You can split the model into layers and apply different slicer settings for each. The thicknesses in these slicing settings will also determine how much material is used in every layer while printing. 

Once your helmet 3D print model is finished, you’ll want to split it into two separate pieces so that you can print each piece separately. To do this, look for an icon that looks like the one pictured below in your software. Click on it and select “Split by thickness” or “Cut all around.”

Step-4: Generating G-code

In your 3D modeling software, you will want to generate the G-code based on your model. The G-code is a set of instructions that your printer understands. You can use it when printing out your design. The G-code generation phase selects a slicing program such as Cura or Slic3r. 

Then enter an additional dialogue where you can select all the necessary slicing parameters like layer height and extrusion pattern. During the slicing process, the GCodeis generated according to these settings. You can save it to a separate file. It will open later in the printing program.

Step-5: Print Orientation

You may want to print your cosplay helmet upside down to make it look more like your favorite one. The number of printers that use the G-code format is growing every day. Changing the orientation of your 3D printed design all happens in the same way. 

Go back into your modeling software and click on Print G-Code again. Then choose “Print Orientation.” It will allow you to select different options for your object’s look when printed in 3D.

Step-6: Removing Supports

Supports are what a 3D printer uses to help objects stay in place while you are printing. It could make it extremely difficult to get support material to stay in place under details.

To solve this problem, you tell your 3D printer to print supports that stick up from the rest of your object. You can use these supports as a base for the rest of your model. It helps hold it in place during printing.

Step-7: Parts Joining

Now you have to combine all the parts to give it full shape. If you want to print two helmets, you will want to join the parts together–but do it carefully. When you want to print one or two helmets, there are limits to what a 3D printer can do.

That’s why I recommend joining your parts together to make it easier for a printer to read out your design. To do that, click on “Join Parts.” You can choose the part you want to join your design into one larger part.

Step-8: Sanding

You will want to file and sand the 3D-printed design when you’re done printing. Sanding helps smooth out the edges and makes it look more finished. To do this, you’ll want to use many different tools. There are several different sanding sticks available online. 

The number is available with varying degrees of grits. Some sandpapers work on wood, plastics, and other materials. Or you can get another type of sandpaper meant for metals, which works better on softer materials like P.L.A.

Step-9: Priming

Once the 3D printed design looks pretty good, you would like to prime the design and bring it out of its raw look. Priming your 3D printed work removes the layer of white plastic. When exposed to oxygen or other gases such as water, it forms on some materials. 

So, the object looks like an actual painted object instead of a 3D printed one. There are different primers available online. Many of them are based on epoxy, and you can use a spray gun to coat large areas quickly.

Step-10: Let’s Start Painting!

After you sand the helmet 3D model, it is ready for painting. Let’s make it look more like a piece of wearable 3d printing clone armor. For example, you can use a few different metallic paints to shine and brightness your helmet. 

There are also some other methods for painting and decorating your 3D-printed part. Some people add extra details by using different materials, feelings, or cloth to their final version.

Related Posts

Top Models of 3D Printed Helmet

In the past few years, 3D printers have been doing a fantastic job fabricating all sorts of objects. Recent research has shown that these 3D printers can produce complex objects without any material wastage.

Here are some of the top and most impressive models to choose from:

1. Sabine Wren Helmet

Wren designed and produced the helmet prints. The 3D printed version of the Sabine helmet worn in the Lord of the Rings trilogy. Wren used a 3D printer with two nozzles to create this amazing helmet: P.L.A. and A.B.S. He stacked the materials and placed them on a flat surface at an angle.

2. Iron Man Helmet

This is the top model of the 3D Print Iron Man Helmet that was 3D printed using an open-source printer. The helmet cosplay is 21.5 cm in diameter and weighs more than 4 kg.

It has several tiny lights embedded inside its outer shell, and it also has tiny servos embedded inside its cap to enable a visor to tilt and nod up and down in response to the movements of the head.

3. Rey’s Star Wars Helmet

Rey’s 3D printed Star Wars Helmet called RepRap at the 3D Print Lab at the Wellcome Trust Sanger Institute. The 3D Print Lab used P.L.A., A.B.S., and T.P.U. for this helmet. It took the institute’s researchers almost a day to print the helmet’s parts and two days to print it completely. 

4. Han Solo’s Sandtrooper Helmet

Lando Calrissian’s helmet from Star Wars is 3D-printed. The helmet was designed by Dave Dorman and printed by Dr. Justin Hamilton from 3D Prints using P.L.A. fabric. His head measures about 14 centimeters or 5 inches in diameter, and he weighs about 3-4 kg. 

Frequently Asked Questions (F.A.Q.’s):

  1. What size printer do I need to make helmets?

The difference between a printer that supports 28.3mm and 30mm. That means 3D-printed helmets work best on printers with an X-size of either 28.3 mm or 30 mm. For making a helmet, you need Creality CR-10S.

  1. How Much Does It Cost To Print A 3d Helmet?

3D cosplay helmets can cost anywhere from $5 – $1000 depending on the design, complexity, and brand. They range from simple plastic shells with labels to complex designs with working interiors.

  1. How Much Does A 3d Printed Helmet Weigh?

A 3D printed helmet weighs about half as much as a traditional helmet. The helmet weighs between 500g – 1600g without head padding depending on the design.

Final Words!

This post really comes in handy for those people who want to make their own 3d printed helmet without burning the midnight oil! And you can also make it by yourself with customizing. Each step needs precision and patience to create a durable and functional object.


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