My wife and I are doing a Pop Art themed Halloween night. I recently purchased a 3D printer and have dived heavily into 123D Design and Cura to print some original prints and some sourced prints. This is my way of giving back a little for others in the diy community. Every file I have made will be free to use by you. Enjoy!
Step 1: Concept
I downloaded a pop art type of font called Adventure. I then looked at a bunch of images and made the pop out bubbles after typing the words in Adobe Illustrator I created an enclosure for the words. For the "POW" it was more of a webbing type and for "BANG" it was more of the starburst bubble. I then enclosed them in triangles and used a speech bubble for the center which came to me as I was designing and probably because I saw it in google a million times.
Step 2: 3D Printing
I exported as SVG file from Adobe Illustrator and then imported the SVG file into 123D as a 2D sketch. After I extruded the image 10mm High, I sized it to approximately 125mm Long and 45mm Wide. After filleting some edges for that rounded look I sent to Cura to create gcode for printing (settings will heavily depend on your 3d printer). The most versatile part is the clip on the back which slides over a button and will attach to an average sized button, it is very simple and something that I will use in future designs. I included the clip as an additional separate file if you wanted to use it for other things, but the STL has it already. The print time was approximately 3 hours.
Step 3: Painting
My costume has hints of purple so I wanted to keep it that color. The filament for the 3d printer is white so I just spray painted it purple. I did the back first let it dry then flipped it over.
Step 4: Finishing Touches
Because I painted a dark color I needed the words to "pop" without coloring too much as I wanted to show off that 3dprintedness of it all to my friends. I would really love to see what some people might do with the color scheme and who have much more skill in painting than I do, please share! Again, all the files are for you to tinker as you wish, if I missed something or you have any questions feel free to ask and I'll do my best.