01 / Challenge
Challenge
A costume maker needed a helmet that fit a specific head scan, printed in a build volume less than half its size, with no visible joins after paint.
Prop and Costume Fabrication — 2025
Titan Helmet Prop
A wearable screen-accurate helmet printed in eight sections, seam-welded, filled and finished to a mirror automotive paint.
PLAFDMRetail
Preparing 3D view
Loading geometry and materials.
- Project
- Titan Helmet Prop
- Material
- PLA
- Technology
- FDM
- Print Time
- 41 hours
- Layer Height
- 0.20 mm
- Weight
- 890 g
- Dimensions
- 280 x 300 x 340 mm
- Industry
- Retail
02 / Design
Design
The shell was scaled to a head scan with 6 mm of internal padding clearance, then split into eight sections with interlocking keys along seams that follow the design lines.
03 / Printing Process
Printing Process
Printed in PLA at 0.2 mm, sections welded with a hot-air tool, then filled, sanded through five grits, primed and finished in automotive base coat and clear.
04 / Final Result
Final Result
No seam is visible under gallery lighting. The finished helmet weighs 890 g and has been worn at three conventions.
Gallery
Through the build
Four moments from the job, in the order they happened.
- 01
Eight sections before welding - 02
Seams filled and sanded - 03
Primed shell - 04
Final automotive finish
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Titan Helmet Prop
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