Zabstract
New Member
Hello everyone! Following my first convention I’ve decided to finally post my ODST build! Hopefully I can explain my process well enough, and answer any questions along the way.
For my first fully 3D printed cosplay armor I wanted to tackle something manageable and not as daunting as a full spartan suit. The suit was made in roughly 7 months in conjunction with the Commando LMG and a Helldiver suit for a friend of mine.
As far as just working on the ODST suit goes:
Oct 2024 - Nov 2024 Printed over the course of 30 days, including failures
Dec 2024 - Jan 2025 Next 60 days spent processing. Sanding/ Filling Etc.
Feb 2025 - April 2025 Painting and Weathering
May 2025 - Sporadically adding more details and finally Rigging and Suiting Up 3 days before the first convention.
Helmet cast & visor: branfuhrstudios
Armor: aguilarworkshop
Thigh plates : titlewavedesigns
Rucksack/leg pouches and bandolier: skookumprops
Commando LMG : blazingforge
Printer: BambuLab P1S
Filament: SUNLU PLA+
Paints Used
Krylon Satin Midnight Garden
Rust-Oleum Ultra Matte Slate
Krylon Deep Gray
Rust-Oleum Flat White
Rust-Oleum Flat Black
Rust-Oleum Metallic Silver
Rust-Oleum Truck Bed Liner
Initial Sanding at 80 Grit using a corner sander/hand sanding. Followed up with a bondo/acetone slurry. I would then go on to applying then sanding several layers of Rust-Oleum 2 in 1 Filler and Sandable. 220->320->400 Grit
At this point I did a test fitting and ended up reprinting the chest plate to be a bit larger. I experimented with using UV resin on it as a filler. I will probably use this method more on future projects.
After sanding and priming I applied a few coats of Rust-Oleum Metallic Silver to all of the armor pieces in order to create the chipped paint look with some masking. I used mustard for this since it was readily available.
It was around this time that I decided to swap out the thighs from those seen in Halo 3 ODST to the ones seen in Halo Reach. Mostly because walking was already and issue with the shins/calves and I also wanted to be able to sit down. In the future I would likely want to remake the entirety of the legs out of EVA Foam.
Began the painting process with Krylon Satin Midnight Garden as my primary color. With Slate, Deep Gray, and Flat White/ Flat Black as accents. Throughout the process I did encounter a bit of " orange peel" or "crazing." Primarily on the thigh plates and a little on the gauntlets. I live in Arkansas where the weather is never the same for more than 2 days and its always humid so... I decided to let it be and make note of it for next time I decide to make a suit.
Used stencils cut with a vinyl cutter to add details to the chestplate and the helmet. Did a bit of silver dry brushing. After clear coating I applied a black wash using black oil paint and mineral spirits.
After sealing the wash with another clear coat I would apply Fuller's Earth dust to most of the armor to make it a bit more grimey. Most of my approach at weathering comes from OddViking's YouTube series on it. At this point I was mainly working on all the extra bits and pieces. Flashbangs, grenades, medkit, biofoam, leg pouches, bullet belts. Anything that I could add on to the kit.
I would also print a neckseal using TPU as well as attach some paracord and a NVG mount. I would also rig my battery for the fans onto the back of the helmet using Velcro.
Most of the rigging follows AguilarWorkshop's Guide for the files. I used a plate carrier vest to house the chestplate, rucksack, and the various accessories.
Here's the final look
And a few pictures from Fan Expo Dallas 2025 at the 405th Booth!
After a first run I did encounter a few complications and also have to make some repairs. 4/6 flashbangs did not survive and I will be revisiting how to mount those. The pivot points on the shins that interlock with the calves snapped as well so I moved around some strapping to keep them together for a majority of the convention. I'm also considering swapping to the Halo Reach ODST shins since I printed those as well but never finished them. Overall I'm happy with how this build turned out and learned a lot along the way that I will use in the future.
For my first fully 3D printed cosplay armor I wanted to tackle something manageable and not as daunting as a full spartan suit. The suit was made in roughly 7 months in conjunction with the Commando LMG and a Helldiver suit for a friend of mine.
As far as just working on the ODST suit goes:
Oct 2024 - Nov 2024 Printed over the course of 30 days, including failures
Dec 2024 - Jan 2025 Next 60 days spent processing. Sanding/ Filling Etc.
Feb 2025 - April 2025 Painting and Weathering
May 2025 - Sporadically adding more details and finally Rigging and Suiting Up 3 days before the first convention.
Helmet cast & visor: branfuhrstudios
Armor: aguilarworkshop
Thigh plates : titlewavedesigns
Rucksack/leg pouches and bandolier: skookumprops
Commando LMG : blazingforge
Printer: BambuLab P1S
Filament: SUNLU PLA+
Paints Used
Krylon Satin Midnight Garden
Rust-Oleum Ultra Matte Slate
Krylon Deep Gray
Rust-Oleum Flat White
Rust-Oleum Flat Black
Rust-Oleum Metallic Silver
Rust-Oleum Truck Bed Liner
Initial Sanding at 80 Grit using a corner sander/hand sanding. Followed up with a bondo/acetone slurry. I would then go on to applying then sanding several layers of Rust-Oleum 2 in 1 Filler and Sandable. 220->320->400 Grit
At this point I did a test fitting and ended up reprinting the chest plate to be a bit larger. I experimented with using UV resin on it as a filler. I will probably use this method more on future projects.
After sanding and priming I applied a few coats of Rust-Oleum Metallic Silver to all of the armor pieces in order to create the chipped paint look with some masking. I used mustard for this since it was readily available.
It was around this time that I decided to swap out the thighs from those seen in Halo 3 ODST to the ones seen in Halo Reach. Mostly because walking was already and issue with the shins/calves and I also wanted to be able to sit down. In the future I would likely want to remake the entirety of the legs out of EVA Foam.
Began the painting process with Krylon Satin Midnight Garden as my primary color. With Slate, Deep Gray, and Flat White/ Flat Black as accents. Throughout the process I did encounter a bit of " orange peel" or "crazing." Primarily on the thigh plates and a little on the gauntlets. I live in Arkansas where the weather is never the same for more than 2 days and its always humid so... I decided to let it be and make note of it for next time I decide to make a suit.
Used stencils cut with a vinyl cutter to add details to the chestplate and the helmet. Did a bit of silver dry brushing. After clear coating I applied a black wash using black oil paint and mineral spirits.
After sealing the wash with another clear coat I would apply Fuller's Earth dust to most of the armor to make it a bit more grimey. Most of my approach at weathering comes from OddViking's YouTube series on it. At this point I was mainly working on all the extra bits and pieces. Flashbangs, grenades, medkit, biofoam, leg pouches, bullet belts. Anything that I could add on to the kit.
I would also print a neckseal using TPU as well as attach some paracord and a NVG mount. I would also rig my battery for the fans onto the back of the helmet using Velcro.
Most of the rigging follows AguilarWorkshop's Guide for the files. I used a plate carrier vest to house the chestplate, rucksack, and the various accessories.
Here's the final look
And a few pictures from Fan Expo Dallas 2025 at the 405th Booth!
After a first run I did encounter a few complications and also have to make some repairs. 4/6 flashbangs did not survive and I will be revisiting how to mount those. The pivot points on the shins that interlock with the calves snapped as well so I moved around some strapping to keep them together for a majority of the convention. I'm also considering swapping to the Halo Reach ODST shins since I printed those as well but never finished them. Overall I'm happy with how this build turned out and learned a lot along the way that I will use in the future.
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