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Full Size Darth Vader Helmet from Star Wars

by Orcdoc Sep 30, 2017
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On my Iron Man helmet I used 2x6mm magnets from Ebay. Drill into the edges anywhere both parts are at least 3mm thick and epoxy opposing magnets in each side. Do one pair at a time and tape over and hold up tight while the epoxy sets so the magnets sit flush. When set, remove tape

I plan to print the mask using clear filament that way won't have to dremel out the eyes

that's not gonna work so well for you but good luck

Any chance posting the whole model helmet model, I want to print in mini version on my resin printer.

Done. I have run it through Netfabb and it should be all go to print.

Awesome, thanks !

This helmet is awesome. Thanks a lot for the upload.. I have printed all the parts, and now I am with the assembly work. How can I do to make it wearable? Any photos from anyone who has solved this?
I'll upload my make when finished

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Thanks a lot for creating this! Had a lot of fun printing and painting this one

Hey there. Im having probs printing the face part. In what position in the printing bed did u print it?

Hi, I ended up printing it upright. I used Cura and selected make overhangs printable, it made the inside of the mask a bit thinker in places and much easier to print.

Okidoki..well im printing it another way and it´s not going so good..if this doenst work ill try it upright as u did..thanks in advance ;)

Thanks for the print. Mine turned out awesome! https://youtu.be/EbGfRjAHI6w

You are welcome, just watched your video, the helmet came out great! I've left a comment on the video for you.

hello, is it possible to wear it?

Hi 3I3m3nt, it should be with a bit of work. I hollowed it out, so it should be able to be worn as a helmet. I haven't had time to finish my print properly as yet, but I taped it together and all the pieces fit together and it fits on my head.

ok thanks :D

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Hi Orcdoc
I have a CR-10S 400 x400 I can print this out in 2 section do you have the file as a mask and helmet you can upload or how can I put the peace to gather please let me know

Hi inetsoho, I've just uploaded the full dome as a single mesh. I look forward to seeing your print.

Hi inetsoho, I will see if I get a chance to put the pieces together for you over the next day or so. I’ll post the pieces here.

Looking at printing this. I was wondering how many kgs of filament this used to print. From my estimates it is 2-3 spools with supports?

If I remember I used about a roll and a half, which included a couple of failures. I sliced in Cura and used the make the Overhang Printable option on the mask, neck and back pieces, which cut down the needed support a lot. I used minimal support for the dome top, so the inside is a bit rough, but it won't be seen. The rest of the lower helmet pieces shouldn't need support as long as you place them well on the bed.

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Yes... very nice. Thank you Orcdoc
Waited a long time for a printable Darth-Vader helmet.
I printed a lot of helmets. ...look at my mades.
This is the next projekt for me.
I will post pictures of the helmet.

Hi there, really like the look of the model. Any chance the eyes lenses could be removed so we can make wearable helmets?

Many thanks

Hi Anthony.
I left the eyes in basically to make it easier to print. I'm just planning to Dremel them out and fill the edges when I get around to it.

will it fit if I set scale 0.86(printer is a little small)

Hi ATOM0220, it should fit, but the walls on the mask sections might be a little thin.

Nice one! Does it fits to head?

Nice model. Wondering what people use to put it together so it can be worn, in particular the back of the neck. Obviously a head wouldn’t fit if it was glued together. Some sort of Velcro attachment?

My plan is to glue the dome together as a single piece, clean up, sand and paint it up and then do the same with the face mask, the chin/neck piece and the back of the mask, but keep them all separated. I'm going to get some fairly strong magnets and work out a way to attach them to the inside of the pieces so I can just clip it all together, but it can easily be pulled apart if I need to.

Looks awesome! might have to give this a go! is it scaled to fit?

Thanks Gzzmos. I scaled it to match the EFX helmet dimensions. So, it is pretty big, I don’t think it is actually as big as the ones David Prowse wore, but its close. I’ve printed all the parts and they have all come out well. I will post some photos ASAP.

Cool! i have a EFX and it fits me very well.
Looking forward to those photos!

this is awesome, i've been waiting a long time for a good vader helmet

thank you

You are welcome. I look forward to seeing your print.