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Incredible 3D Printed Helmet Designs You Will Love to Make

3D printing enthusiasts love making 3D printed helmet props from video games and movies that have become classics. The variety of cool designs, custom projects and cosplay ideas meet even the most strict tastes. Thus, you can always find the full size or small versions of helmets to make with a 3D printer for yourself, your friends and kids.

From Star Wars, Mandalorian, Boba Fett, Iron Man, and to great Spartan DIY projects, you can 3D print the full-size wearable helmet of your dreams.

3D Printed Helmets

The astonishing 3D designs of the 3D printing helmets you will see below are inspired by popular video games, movies, comic book characters, and life. A legion of fans worldwide with a 3D printer at home will admire this selection.

Be it a holiday assignment or a surprise 3D printing project, the custom helmets and ready-to-print pieces look truly unique and deserve to appear in your collection.

1. 3D Printed Iron Man Helmet

Fans of Iron Man will love to 3D print a wearable prop of their hero. All you need are helmet STL files or good instructions on making a custom model yourself, from 3D modelling to painting the finished 3D printed project.

Helmet STL

Recent films featuring the Iron Man have catapulted the character to incredible popularity. Wearing a 3D printed Iron Man helmet gives the wearer that movie character allure that we’re all familiar with.

There are various 3D printed helmets designs of Iron Man on the Internet. The one featured in our selection is great to make because its creator shared the step-by-step instructions with everyone who intends to 3D print this masterpiece.

3D printed Iron Man helmet

The enthusiast provided both the STL and OBJ file formats so you can get the files your 3D printer supports.

2. 3D Printed Mandalorian Helmet

DIY Mandalorian helmet has been a real trend of the last couple of years. Ever since the release of The Mandalorian TV series, many cosplayers and hobbyists have enjoyed turning themselves into Mando by wearing his costume.

Hobbyist jstayton26 has alienated himself from the over-replicated props and created the full-size Mandalorian helmet 3D model. The project is split into eight pieces, which you can recreate using a 3D printer. It is fun to paint the piece according to your liking.

3D printed Mandalorian helmet

Go ahead and download the Mandalorian helmet 3D file for printing at Thingiverse.

Also, you can extract Mandalorian helmet STL files from the stunning Mando figurine for 3D printing you will find on gambody.com. Enthusiast Tom Anton used these files to 3D print a full-size prop. He finished his cosplay outfit with armour resembling what Din Djarin wears in the TV series.

3D printed Star Wars helmet
Photos by Tom Anton

You can even make yourself a bag and place a 3D printed Baby Yoda figurine inside. This way, your DIY Mandalorian helmet will distinguish you from other assassins. Unlike others, you will protect the Child and receive many compliments on your costume.

3. 3D Printed Star Wars Helmet

Star Wars is an insatiable source of inspiration for every cosplayer in the world. With many fictional characters, badass droids and soldiers, new inspirational 3D printed helmets appear every year.

It is more likely for any cosplayer with a 3D printer at home to recreate the well-known Darth Vader, Stormtrooper, Boba Fett props using detailed 3D print files or build a replica of Luke Skywalker’s lightsaber.

3D Printed Stormtrooper Helmet

Fans of Star Wars films who love making cosplay props will enjoy a stunning 3D printed Stormtrooper helmet. It is probably one of the most recognized items to the space opera series fans.

3D printed Stormtrooper helmet

The latest Episodes VIII (The Last Jedi) and IX (The Rise of Skywalker) made this item reborn more potent than ever. Only look at the 3D printing model created using Blender software. It consists of 22 parts that must be super-glued together and painted to make it look just like the Stormtrooper helmet in the movie.

Boba Fett Helmet 3D Print Files

The former bounty hunter Boba Fett is an iconic character whose story began in the Star Wars movies and continues in The Book of Boba Fett TV series.

Boba Fett helmet 3D print files
Image: CGTrader

You can find Boba Fett helmet 3D print files on different marketplaces to create such a prop for yourself. While it looks like the one worn by Din Djarin, it has distinguishing features, such as an antenna and particular colours. So paint it correctly and enjoy wearing it for various costume parties.

3D Printed Darth Vader Helmet

Our list of cool 3D printed helmets from the Star Wars franchise will never be complete without a Darth Vader prop. The antagonist in the original movies and protagonist in prequels is easily recognized for his headpiece.

Only think about your finished 3D printed Darth Vader helmet covering your face behind the mask. No one will even recognize you if you wear this black prop complimented with a dark coat for a party.

3D printed Darth Vader helmet
Pictures: CGTrader

One of the most notable fictional characters ever existed cannot wait for you to work on its prop. So, get the Star Wars helmet STL files and spend some time printing this thing on your 3D printer.

Kylo Ren Helmet STL

When you are looking for even more 3D printed Star Wars helmet ideas, think of making a Kylo Ren headpiece. It is recreated from Star Wars Episode VII. It is the miniature version, while a wearable piece is still being made.

Kylo Ren helmet STL

Turning into a Sith Lord hasn’t been more accessible than 3D printing a project just like his. You will need to use supports while breathing life into the Kylo Ren helmet STL files, but this 3D model can improve your collection.

4. 3D Printed Master Chief Helmet

Many Xbox One owners have played the Halo games. If you are one of them, work on a 3D printed Master Chief helmet. Such a project can be done for kids and adults because its free STL files are designed in several sizes.

If you look closer at the 3D printed Master Chief helmet you will notice how close this replica is to the video game prop. It was designed in Autodesk Fusion 360, and this Halo accessory makes a perfect cosplay item.

3D printed Master Chief helmet

It will take about 60 hours to print it at 0.2mm layer height with 5% infill.

5. 3D Printed Spartan Helmet

For 3D printing a helmet, a 3D printer is a must-have, along with detailed STL files. Take a chance if you enjoyed the 300 (film) and wish to transform into one of the 300 Spartans to battle against the invading Persians.

3D printed Spartan helmet
Images: Cults

Thanks to the fun warrior prop STL files, you can add a 3D printed Spartan helmet to your wardrobe. The author of this project used a brush to create the mohawk style on top of the wearable accessory.

6. 3D Printed Destiny Helmet

Your helmet 3D print could resemble the piece from the Destiny video game. You can recreate the Mask of the Third Man using your 3D printer and Destiny helmet STL files.

3D printed Destiny helmet
Pictures: MyMiniFactory

Of course, your finished 3D printing model will lack all virtual perks. But this piece will look fantastic, significantly if you can add LEDs to light it up. Being a three-eye hunter should be awesome if you plan to go to a cosplay event or costume party.

Your 3D printed Destiny helmet will be made of several parts, which you should glue together.

7. 3D Printed Captain America Helmet

The leader of the Avengers team, America’s World War II Super-Soldier, is a popular Marvel character among cosplayers. To prove that heroes live among us, you can work on your 3D printed Captain America helmet.

Download these or those STL files and let this prop be one of the most fantastic 3D printed helmets in your collection.

3D printed Captain America helmet
Images: Thingiverse; Pinshape

Paint the piece in the colours of Captain America (blue, red and white) or leave your 3D printed helmet black.

8. 3D Printed Doom Helmet

Those 3D printing enthusiasts who love first-person shooters and are big fans of the Doom video game will be happy to see this 3D printed helmet. Once you paint this prop into life-like colours, it will look like the one in the game.

3D printed Doom helmet
3D model: prusaprinters.org

Turn into the Hellwalker and amaze everyone with your unique 3D printed Doom helmet at the costume party. Such a DIY project will last for years and make you proud of yourself.

9. 3D Printing Helmet for Everyday Use

Many enthusiasts with a 3D printer at home love to work on various things to improve their everyday life. Making 3D printed helmets can be fun for kids’ parties as little boys love dressing as knights, samurai, astronauts, space travellers, and football champions.

3D printed knight and astronaut helmet
3D models: Cults

And adults could use their desktop machines to 3D print a headpiece for their personal needs, such as a motorcycle or bicycle ride. However, such projects might not meet safety standards if made with a regular 3D printer at home.

10. Avengers Ultron 3D Printed Helmet

Among 3D printed helmet files, you will notice a model from the Avengers: Age of Ultron movie. And since the film is based on comic books, it is no surprise it has a huge fan base.

This fully wearable 3D printed Ultron prop was inspired by the movie’s supervillain character. The mask was modelled in 4 separate parts to facilitate its printing: the jaw, the main face, the top of the prop, and the ears. Printed at 0.15-0.2mm layer height, the creation of the entire Ultron helmet took about 80 hours of work.

3D Printed Avengers: Age of Ultron Helmet

Once you finish 3D printing all the parts, you will have to assemble the pieces and fill the part lines with putty. After this, paint your 3D print and enjoy wearing it for parties.

11. 3D Printed Helmet from Fallout

Another source of endless inspiration for cosplayers is the Fallout video game. From 3D printed helmets to entire power armour suits, it might seem that every bit of the amazing video game content has already been replicated for cosplay. But, there’s still room for imagination and your approach.

3D printing helmet
Photos: Thingiverse

This T-60 helmet was improved for 3D printing by Jace1969. Today, you can download its files and breathe life into such a fantastic project.

Also, you can recreate the T-51-b Power Armour prop just like the one designed by Daniel Lilygreen. This 3D print consists of 12 separate parts which, according to the creator’s advice, must be glued together, to hold the entire weight.

3D print helmet

12. 3D Printed Star-Lord Helmet

Suppose you’ve seen the acclaimed Guardians of the Galaxy movie. In that case, you will find this 3D printed helmet a fun cosplay prop to behold. Marvel fans can rejoice because you can find a stunning Star-Lord prop for 3D printing and download the model’s STL files to work on your project.

The model was created by the RPF member Helagak, who provides complete 3D printing instructions. You can follow each step and recreate an impressive accessory from Guardians of the Galaxy.

3D printed helmet files

Try to light up the “eyes” to wear this piece in the dark! Everyone will enjoy your new look.

13. 3D Printing Daredevil Helmet

This Daredevil helmet for 3D printing is about 221mm high, 188mm wide and 221mm deep. However, according to the creator, the piece can be scaled either down or up, depending on the wearer. It means that you could also turn into Daredevil if you want.

Helmet 3D printer

The 3D printing model is available for download as STL files, compatible with many affordable 3D printers.

14. Cyberman 3D Printed Helmet Files

Are you a Doctor Who kind of guy or girl? Then this 3D printed helmet is precisely for you. It was a spooky project for Halloween for a father and a son. The 3D model was created entirely in ZBrush modelling software and printed on MakerBot Replicator 2.

The designer behind the epic Cyberman helmet has shared the entire process of modelling and printing this piece here. You will love pictures of the painted work. It looks fantastic!

Helmet 3D print

Cool, huh? These 14 inspiring 3D printed helmet models will put you in the cosplay spirits. Don’t hesitate! Right now is the perfect time to boost your creativity and craftsmanship. And don’t forget to share your 3D prints in Gambody 3D Printing Community on Facebook for the joy of other hobbyists.

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