1st Build Halo Infinite Cosplay - Mark VII (War Master)

[JaderM]

For the longest time, I've been wanting to do a full Halo cosplay, but didn't have the time, money, or materials to do it when I was younger. At the time, I assembled Pepakura models and now finally taking a dive into 3D printing, especially now that I play Halo as my go-to FPS at the moment.

This is my in-game Spartan, just the Mark VII base with the War Master helmet.

For this project, I am using the Bambu Labs P1S 3D printer with an AMS and the Creality Space Pi Plus filament dryer. As for filaments, I intend to use:

- Bambu Labs ASA (for the armor pieces)
- Bambu Labs TPU 90A (for the undersuit pieces)

This is an extraordinarily ambitious project for me, and I hope to complete it before 17 April 2026 for LVL UP EXPO in Las Vegas.

 

[SgtSaint]

Hope this helps:

SgtSaint's FAQ post

So I tend to post this response to the common or Frequently asked questions when people ask on the various social media channels. I copy/paste it to Facebook, or the Discord server and some folks urged me to post it here and just link it in the future. Ok, here goes. These are my tips and how...

www.405th.com

 

[SIERRA720]

That's a sweet looking suit! Always loved desert camo on Spartans

 

[JaderM]

Hope this helps:

SgtSaint's FAQ post

So I tend to post this response to the common or Frequently asked questions when people ask on the various social media channels. I copy/paste it to Facebook, or the Discord server and some folks urged me to post it here and just link it in the future. Ok, here goes. These are my tips and how...

www.405th.com

Luckily, I had already looked at all that stuff before starting this project. Funnily enough, I did the opposite and started with the helmet first because I'm already familiar with working on helmets the most, and are easier to not worry about fitting months prior.

 

[JaderM]

That's a sweet looking suit! Always loved desert camo on Spartans

For awhile I didn't dig camo on Spartan armor until recently, especially with this splinter camo design. But yes, thank you!

 

[JaderM]

ASA is an absolute PAIN to print with, but I got it down now.

Sadly, I jumped the gun and attempted to print the helmet. I had a size ring, and while it would have fit mostly fine (minus the ears, ouch), the way the helmet is designed would not have made it comfortable to take it off (I have taken it off twice, and I never again want to do that).

Additionally, I did not realize how bad bridging was. While I would be fine reprinting it in one go, I resized it back to its original scale instead of the 90% I went for. The thought I had was to keep the helmet as proportionate as possible and not have it oversized.

Here is my sad attempt at a print, but I learned a lot from it and will be using this information carrying forward.

(Bonus timelapse for your amusement!)

I am already starting to reprint the helmet in 5 pieces to retain detail in certain areas, and to keep most of the supports inside the helmet so they are hidden, reducing the amount of post processing I will have to do.

Seeing how the (unfortunate) draft helmet came out, I can use it to print the helmet out more strategically.

I already printed out the first part of the helmet, and it turned out A LOT better than the draft thanks to how I oriented it. I shall showcase the printed pieces once I have them all.