The parts in this kit are designed to be 3D printed with FDM based machines. STL files are oriented to print "as is". Parts require tight tolerances that might need adjustment of slice settings. Reference the suggested settings below.

CAD Files

The parts can further be separated into small pieces for fitting on printers with smaller build volumes. Note: a STEP file is included for other 3D surface modeling programs such as Onshape, Solidworks and Rhino.

Share, Make, Remix

This SpaceX Helmet was originally designed by Nathan O – The files are open to remix and they feature nice details. The parts have been modified to fit all of the electronics and available to download!

Settings

Use these settings as reference. Values listed were used in Cura slicing software.

  • 0.2mm Layer Height / 0.4mm nozzle
  • 0.38mm Line Width (inner & outer widths)
  • 60mm/s printing speed
  • 10% infill
  • Supports: Yes
  • Brim: 7mm

De-Brim

The parts are printed so they lay flush when assembled together. We used a 7mm brim to ensure the parts are as flat as they can be to better align the two halves.  Use flush cutters to help remove the brim.

DeBurr

Next use a deburring tool or a hobby knife to clean up and smooth out the sharp edges.

PanaVise Holder

To keep the parts steady and leveled, I used a PanaVise Jr. to help hold the parts while applying glue.

Super Glue the Edges

Apply a generous amount of super glue to the edges and then carefully align the ends. We used StarBound Medium Dry super glue with a narrow tip to precisely add to the edges that meet together. Apply pressure to help parts adhere.

Hot Glue

Allow the super glue to dry. Next reinforce parts by adding hot glue to the inside of the blade sections. Apply a small amount of hot glue to each section of the screws holes and allow it to dry.

You can also speed up dry times by spraying each section with an Air Duster. This technique is used extensively later in the build. 

This guide was first published on Aug 20, 2019. It was last updated on Aug 20, 2019.

This page (3D Printing) was last updated on Nov 06, 2020.