Introduction: Mandalorian Helmet

Necessary Technology

  • 3D Printer


  • 150 grit sandpaper or something close
  • High grit wet sandpaper
  • Steel Wool
  • Window Tint
  • Chrome Air Brush Paint or Spray Paint
  • Sandable Spray On Primer
  • Some Sort of Filler Puddy (I used Platinum Patch Advanced Exterior Filler from my local Home Depot)
  • Foam Pads

Step 1: Download and Print the Helmet

The first step is to download and print the helmet. I found this guy who made a really good helmet design and which is FREE on The helmet is already split up so the base helmet can be printed in 1 piece, 2 pieces, or eight pieces. You will also have to print the 2 earpieces and the piece at the back of the helmet. Here is the link to the helmet.

Step 2: Break Off the Support Material and Sand

For this step, I used 150 grit sandpaper. The purpose of this step is to sand off any bumpy or small pieces of plastic that protrude from the print. DO NOT worry about trying to get rid of the lines created by the filament printer in this step.

Step 3: Cover the Entire Helmet With the Sandable Filler Putty

Rub the sandable putty on the helmet. Don't put it on too thick or you'll make more work for yourself. Let sit for about 2 hours before moving on to Step 4.

Step 4: Sand

This is the most meticulous part of the process, but it is very important to get right. This is the step that does the most to smooth the helmet and get rid of the 3D printer lines. Sand down the dried putty and use steel wool to help wipe off the dust. The pictures above are what my helmet looked like after this step.

Step 5: Clean and Then Spray on Sandable Primer

Before you spray on the primer it is super important to clean off as much dust as you possibly can. Then spray on the Sandable Primer. Wait for it to dry and lightly sand with high grit wet sandpaper.

Step 6: Air Brush or Spray Paint With Chrome Paint

Spraypaint or airbrush the helmet, the two earpieces, and back piece with your chrome paint.

Step 7: Glue on the Earpieces and Back Piece

Glue on the earpieces and the back piece. Make sure glue is not visible on the outside of the helmet.

Step 8: Add Visor and Padding

To add the visor cut a piece of window tint into shape. Then glue or tape in the visor. I taped it in but this is because I might put on another coat of paint. Add pads on the inside of the helmet so it sits right on your head and is comfortable.

Step 9: Share It With Me!

If you did this project be sure to click the "I Made It" button to share your work with me. I am really excited to see what you can make!

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