Stormtrooper First Order TFA Helmet | Screen-Accurate Star Wars Cosplay Prop

Screen-accurate, wearable First Order Stormtrooper helmet from Star Wars: The Force Awakens. For cosplay or display.
554h 53m
10× print file
0.05 mm
0.40 mm
1152.00 g
897
3793
13
25 k
updated April 17, 2025

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Awesome project and files I am actually printing for a friend 60 birthday...as you can imagine, he is a big fan of Star Wars
for the mesh.3mf file, I will try to print scaled down to 75% to fit the Core one + bed...
I will send update later

hi i love your model but could you add the file for the inside connector please?

hi what helmet suspension do you use ?

Hi, connecting to the question about the glass. How do you use the glass template to shape the glass? Do you have any suggestion? Thanks in advance and and also thanks for the really great model!! (edited)

@LorenzoMonta_2468747 does this help?

Ive found this picture of the process
But it should be exactly the other way around the printed part on the table and the plexiglas on top.
First you heat up the plexiglas and bend it in rough shape.
Afterwards lay it on the template and keep on heating.
So the eyes should go a bit outward down to the table.than you can mark the oter edge and trim the glas.

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@KeepTheBOX thanks this helps a lot to understand the process and the tools to use!

Can anyone tell me the final dimensions of the helmet? I want to print this for my 6yr old but I am not sure how much it would need to be sized down. Thanks in advance!

@AngieEames_3039451 hey i cant give you the Dimensions. But here are two tips how you could sice it.
1. make a objet the sice of your child and scale the helmet to fit it
2. print a cut section of the helmet and try if it fits your child

i wonder if TFA_helmet_v2 final would fit in the ps1 bambu and do a full print ?

Finished mine, at last.
So many mistakes on that way😁

Next time if I decide to print that helmet again I will print it as a whole. And will use automotive putty, primer, and varnish from beginning no paint spray cans.

Thanks for the model!

By the way there is a gap between visor and top part of the helmet on the sides. Noticed very late

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@MoscowVfx_2931913 Sorry if it is a dumb question but, how did you do the glass?

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Are there any template for the glas. And how to make it. The template that are includede does not explain how to greate the glas.

Still printing, one piece on the prusa xl, had to restart after heavy layer shift, but now it runs fine (26h+)

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Love how black and white create gray for your mind only!

Great model. Thanks for sharing it. I love it

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Hello!

May I ask why use ASA instead of common PLA?
Thanks in advance

L

@LorenzoMonta_2468747

The main reason i used it was more heat an impact resistant.
I glued and filled the gaps it with a asa slushy made from supports and aceton,

But if PLA is fine for you it is totaly fine to print it with PLA.

You can find a good overview of the propertys from the different materials here.
https://help.prusa3d.com/materials