1st Build Halo Reach Jorge Armor Build

[VocalicStorm8]

Hey all, new here to the 405th. I’ve printed a few helmets and other stuff in the past for cosplays but now I’m finally doing a full armor cosplay. Going to be cosplaying Jorge from Halo Reach for a con next summer. This thread is just a way to document everything I will be doing as I think it will be a cool way to see my progress over time.



Everything is being printed from a Bambulab P1S using 5% - 10% gyroid infill all done in PLA

 

[SgtSaint]

Summer and "PLA" are not terms that generally go together.
Are you aware that PLA has a 'glass transition temperature' (meaning the point at which it softens and can deform) that is much lower than other materials like PETG or ASA etc. ?
Its always a hotly debated conversation but personally, there's no down side to moving to a better material, and no up side to staying on PLA. There's always plenty of people that will say "I did mine in PLA/PLA+ and its fine" but I have yet to find anyone that can give a *reason* or a *gain* for insisting on using it.
You do you.

 

[VocalicStorm8]

First the helmet

I bought my helmet file from Galactic Armory found here and I used a tape measure to measure the circumference of my head to get the size in Inches ( I have glasses that I wanted to wear underneath the helmet so I included the glasses in the measurement). The head in the picture is a rough size of my own head, files for it can be found here.

It took roughly two days to print and here is how it came out (top attachment not included because I forgot to put it on when taking the picture)

I don't have any pictures but I went over the whole helmet with 320 grit to knock down the rough layer lines and some extra fine steel wool to really smooth it out. Will update with more pictures once I begin bondo-ing and assembling.

 

[VocalicStorm8]

Summer and "PLA" are not terms that generally go together.
Are you aware that PLA has a 'glass transition temperature' (meaning the point at which it softens and can deform) that is much lower than other materials like PETG or ASA etc. ?
Its always a hotly debated conversation but personally, there's no down side to moving to a better material, and no up side to staying on PLA. There's always plenty of people that will say "I did mine in PLA/PLA+ and its fine" but I have yet to find anyone that can give a *reason* or a *gain* for insisting on using it.
You do you.

Luckily the con I'm going to is indoors and has pretty good AC since it's in a large convention center. I've had quite a few PLA printed parts and props melt on me while I was painting/priming them outside so I understand the concern lol.

 

[JP120800]

Luckily the con I'm going to is indoors and has pretty good AC since it's in a large convention center. I've had quite a few PLA printed parts and props melt on me while I was painting/priming them outside so I understand the concern lol.

PLA is fine to use, As the melting point is about 210 degrees celcius. I've never had an issue. If youre worried about temp, depends where youre from. Obviously never an issue in the UK.

 

[pinoyfiasco]

PLA is fine to use, As the melting point is about 210 degrees celcius. I've never had an issue. If youre worried about temp, depends where youre from. Obviously never an issue in the UK.

It's important to note that melting point and glass transition temperature are two different things.

PLA can start deforming at as low as 60°C (~140°F).

Also, PLA's melting point is actually closer to 150°C. 210°C is just a commonly recommended printing temperature for PLA.

 

[JP120800]

It's important to note that melting point and glass transition temperature are two different things.

PLA can start deforming at as low as 60°C (~140°F).

Also, PLA's melting point is actually closer to 150°C. 210°C is just a commonly recommended printing temperature for PLA.

Interesting to know thankyou, didnt know that. Good job that the temperature in England never gets above 30-40 degrees lol

 

[tahu505]

Summer and "PLA" are not terms that generally go together.
Are you aware that PLA has a 'glass transition temperature' (meaning the point at which it softens and can deform) that is much lower than other materials like PETG or ASA etc. ?
Its always a hotly debated conversation but personally, there's no down side to moving to a better material, and no up side to staying on PLA. There's always plenty of people that will say "I did mine in PLA/PLA+ and its fine" but I have yet to find anyone that can give a *reason* or a *gain* for insisting on using it.
You do you.

As someone who lives in a desert where the summers get up to 120°F (~49°C), I have only had PLA warp when sitting in direct sunlight for at least an hour. If it is 120°F outside, you should not be standing outside in direct sun for hours, no matter what material your costume is made of. That is not healthy.

With that in mind VocalicStorm8 , PLA is a great starter material for getting into 3D printing armor since it is easy to print and non toxic. To avoid warping while painting in the summer, you can paint in shaded areas or move the parts to shaded areas while they dry. It's the direct heat from the sun that tends to really get you.

 

[VocalicStorm8]

My first post with the beginning of making the helmet is still waiting for mod approval so I’ll just post this as I wait.

Progress on helmet

I got a hard hat from Home Depot and cut it up so it can fit inside the helmet. I had to cut off about 3 inches of the dome in order for it to sit where I want to. I found that the ratchet one is way better in terms of holding onto my head. The only downside is that others may find that the ratchet gets in the way.

Ordered some spot bondo an Amazon so waiting for that to come in but I used normal automotive bondo for the sides of the helmet to cover up the seam. I’m going to attach the details last as gluing them now will be a pain to paint later.

Here’s how it sits on my head, plenty of room for my glasses and enough inside room for fans and a microphone if I choose to do so.

 

[VocalicStorm8]

As someone who lives in a desert where the summers get up to 120°F (~49°C), I have only had PLA warp when sitting in direct sunlight for at least an hour. If it is 120°F outside, you should not be standing outside in direct sun for hours, no matter what material your costume is made of. That is not healthy.

With that in mind VocalicStorm8 , PLA is a great starter material for getting into 3D printing armor since it is easy to print and non toxic. To avoid warping while painting in the summer, you can paint in shaded areas or move the parts to shaded areas while they dry. It's the direct heat from the sun that tends to really get you.

Thanks for the insight! As someone who lives in South Florida I don’t plan to be outside too long in any cosplay lol.