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3D Printing Helmet Movie Prop

  • Jun 22, 2020
  • 1 min read

Updated: Sep 18, 2024

We wanted to share with you the stages and process by which we fabricated a custom 3D printed helmet, Star-Wars-like movie prop.

We started out by designing the helmet using Fusion360 3D CAD program

  • CAD File for 3D printing for creating a helmet movie prop
    Helmet CAD File
  • CAD File for 3D printing for creating a helmet movie prop
    Helmet CAD File
  • CAD File for 3D printing for creating a helmet movie prop
    Helmet CAD File
  • CAD File for 3D printing for creating a helmet movie prop
    Helmet CAD File

Here is the rendering of the 3D CAD software showing how the end result will look like

  • rendering mock up for a helmet movie prop fabrication
    rendering mock up
  • rendering mock up for a helmet movie prop fabrication
    rendering mock up
  • rendering mock up for a helmet movie prop fabrication
    rendering mock up
  • rendering mock up for a helmet movie prop fabrication
    rendering mock up

Next step was to 3D print all parts on our 3D printer using ABS material

  • 3D printing ASB material for fabricating a helmet movie prop
    3D printing ASB material
  • 3D printing ASB material for fabricating a helmet movie prop
    3D printing ASB material
  • 3D printing ASB material for fabricating a helmet movie prop
    3D printing ASB material
  • 3D printing ASB material for fabricating a helmet movie prop
    3D printing ASB material
  • 3D printing ASB material for fabricating a helmet movie prop
    3D printing ASB material
  • 3D printing ASB material for fabricating a helmet movie prop
    3D printing ASB material

We then glued all layers together, using Superglue, to create the unified helmet.

We sanded the prop using an orbital sander as well as 400 Grit sand paper.

  • 3D printed helmet prop for fabricating a movie prop
    3D printed helmet prop
  • 3D printed helmet prop for fabricating a movie prop
    3D printed helmet prop
  • 3D printed helmet prop for fabricating a movie prop
    3D printed helmet prop
  • 3D printed helmet prop for fabricating a movie prop
    3D printed helmet prop

Once done with sanding, we applied Spackle over all layers glued lines to get rid of the visible print lines, and then sanded some more

  • Spackle over 3D printed helmet fabricating a movie prop
    Spackle over 3D printed helmet
  • Spackle over 3D printed helmet fabricating a movie prop
    Spackle over 3D printed helmet

In the next step, we sprayed 6 coats of filler primer. We sanded again each layer once dried to get the desired smooth finish


  • 3D printed helmet movie prop with filler prymer prior to painting
    Filler Primer on helmet prop
  • 3D printed helmet movie prop with filler prymer prior to painting
    Filler Primer on helmet prop
  • 3D printed helmet movie prop with filler prymer prior to painting
    Filler Primer on helmet prop
  • 3D printed helmet movie prop with filler prymer prior to painting
    Filler Primer on helmet prop
  • 3D printed helmet movie prop with filler prymer prior to painting
    Filler Primer on helmet prop
  • 3D printed helmet movie prop with filler prymer prior to painting
    Filler Primer on helmet prop

Once the helmet was smooth enough we painted it using automotive metallic paint


  • 3D printed helmet movie prop with automotive paint finish
    Automotive painted helmet

The last stage was to add the visor. We used a thick one that would not bend yet would still be transparent


3D printed helmet movie prop with automotive paint finish
3D printed Helmet Prop
  • 3D printed helmet movie prop with automotive paint finish
    3D Printed Movie Prop
  • 3D printed helmet movie prop with automotive paint finish
    3D printed helmet prop

If you want to see more of our 3D printing projects and our prototyping projects, visit us at https://www.wecutfoam.com/3d-printing-foam-modeling and https://www.wecutfoam.com/cnc-prototyping









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