3D printing has transformed cosplay. Helmets, gauntlets, blasters and badges that once took weeks of foam work can now be printed. Here's how to get convention-ready results.
1. Choose and split your model
Big pieces like helmets usually need splitting into sections that fit your printer. Many slicers can cut models, and designers often supply pre-split files. Add alignment pins or keys so parts line up.
2. Pick the right filament
- PLA is easy to print and sand. It's great for props that stay out of hot cars.
- PETG is tougher and less brittle for armour that gets bumped.
- Light infill (around 10–15%) with more walls keeps pieces light but strong.
3. Join the parts
4. Sand, fill and prime
This is where the magic happens. Sand with progressively finer grits, fill seams and layer lines with filler primer, and repeat until smooth.
5. Paint and weather
Base coat, then add depth with washes and highlights. Metallic paints and a little dry-brushed silver on the edges make armour look battle-worn. Seal with a matte or satin clear coat.
No printer, or a deadline looming? Upload your files and we'll print your pieces in Logan.
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