xcopy's 3D printed helmet WIP

[xcopy]

Hi everyone,

I have been working on a 3D printed helmet as a bit of a test to see if I can hand make a full set of armor that meets level 1 CRL.  Any and all feedback is welcomed. Here it goes!

Original helmet model (surfinbird132): https://www.thingiverse.com/thing:3416367
Material: Gizmo Dorks 1.75mm HIPS grey https://www.amazon.com/Gizmo-Dorks-1-75mm-Filament-Printers/dp/B00GU2O56C/ref=sr_1_3?dchild=1&keywords=1.75mm+hips&qid=1584305423&sr=8-3
Printer: Custom 280mm x 280mm x 410mm corexy based FDM
Print settings: bed - 115C, nozzle - 250C, nozzle size - 0.4mm, layer height - 0.24mm, infill - 10%, speed - 100mm/s
Helmet paint: Rustoleum 2X white primer & gloss white
Detail/graphic paint: Testors Dark Gull Grey & generic craft store black acrylic

This is the current state.

[xcopy]

It's cold in my garage and HIPS should be printed in a heated chamber, so I created a makeshift one using a heated blanked.

This is what the parts look like after printing. The support material is a bit messed up due to the heat of the chamber, but the parts still turned out well.

The helmet model has a couple of features that I modified in order to be more screen accurate, one of the is the vents.

So, I sanded down the sharp edge and filled/widened the rim of the vent using cotton (from cotton balls) and super glue.

And from the side.

I also filled in the nose vent using the same cotton/super glue method.

Rather than cotton/super glue, I used baking soda & super glue to fill the forehead ovals.

Test fit.

I sanded with 150 then 220 grit sandpaper and glazed everything using Bondo Glazing and Spot putty. I also created a modified model for the vent covers on the back of the helmet to eliminate the holes.

Ready for primer.

After primer. The visor is made out of 5% VLT window tint.

I painted each piece with gloss white and created stencils for the graphics using a my homebrew 2.5W laser cutter.  Let me know if you are interested and I can share my drawings. This is the visor graphic stencil before painting.

And after painting.

I used the same stencil/paint method for the nose vent. This is the first layer.

This is what the masking looked like for the second layer.

Same deal for the forehead stripes.

The last thing I did today was hand paint black around the greeblie. Next up is the black stripes and rear vents. Stay tuned!

[Stickleggs]

I'm interested in seeing this during the approval process.