Custom Plastic Cosplay Helmet
Budget: $250 – $750 USD
I'm looking for a skilled 3D CAD Artist to create STL files for a cosplay helmet.
Ideal Skills and Experience:
- Experience in designing helmets for 3D printers
Project Goal
Design a wearable, 3D-printable sci-fi helmet based on supplied concept art, optimized for:
• Long-duration cosplay wear
• Active airflow
• Thick motorcycle helmet padding
• Rear-mounted power system
• Anycubic Kobra 2 Neo print constraints
USER ANTHROPOMETRICS
• Head circumference: 22.25 in / 565 mm
• Target padding clearance: 15–20 mm
• Helmet internal allowance: Sized for motorcycle helmet padding (multi-density foam)
Internal clearance requirements (minimum)
Crown 20mm
Temples 15mm
Back of Head 18mm-20mm
Cheeks ~15mm
Brow - Forehead ~15mm
VISOR SYSTEM
• Visor source:
JT 23262 Elite Prime Single Goggles (paintball visor)
• Design approach: Helmet geometry conforms to visor, not vice versa
Visor mount requirements
• Internal visor lip: 3–4 mm
• Light-blocking overlap (no internal glow bleed)
• Secure retention (screw or clip-based)
• Visor removable without destroying helmet
SHELL CONSTRUCTION
Shell thickness
• 3.2 mm nominal
• ±0.3 mm tolerance acceptable
Helmet type
• Fixed shell
• No hinges or face opening
Exterior style
• Aggressive, intimidating
• Predator-inspired helmet silhouette
• Sleeker, less bulky than Halo MJOLNIR
• Rear mass intentional (fans + battery)
AIRFLOW SYSTEM
Fans
• Quantity: 2
• Type: USB blower fans
• Size: 50 × 50 × 15 mm
Fan placement
• Both fans housed in rear helmet volume
• Vibration-isolated mounts
• Fans not directly adjacent to padding
⸻
Airflow routing (CRITICAL)
Fan A — Anti-fog visor airflow
• Duct from rear → visor interior
• Exit slit positioned to blow across visor surface
• Avoid direct airflow into eyes
Fan B — Breathing airflow
• Duct from rear → mouth/chin area
• Slight downward angle
• Designed to reduce CO₂ buildup
Ducts must be:
• Integrated into shell geometry
• Smooth internal curves (no sharp corners)
• Sealed (no air leaks into padding foam)
POWER SYSTEM
Battery
• Dimensions:
2.7” × 2.75” × 0.9”
≈ 69 × 70 × 23 mm
• Type: USB power bank
Battery location
• Rear of helmet
• Dedicated rigid pocket
• Padding-isolated
• Heat-isolated from head
Battery access
• internal hatch
• User-accessible without tools
FASTENERS — BATTERY HATCH
Coin-slot screw
• 3D printable
• Flush with helmet surface
• Coin-compatible (penny / dime)
• Captive design (cannot fall out)
• Threaded into printed boss or embedded nut
Design intent:
• Stealth exterior
• Convention-friendly battery swaps
ELECTRONICS & WIRING
Switch
• Inline power switch
• Mounted internally near rear / neck edge
• Reachable while wearing helmet
• Visually hidden
Wiring
• Integrated wire channels
• Strain relief at:
• Fan connections
• Battery output
• No loose cables inside helmet
PADDING SYSTEM
• Padding system similar to motorcycle helmet padding
• Thick, removable, washable pads
• Velcro-compatible interior surfaces
• No interference with airflow ducts
• Padding must not block fan outlets
PRINTING CONSTRAINTS
Printer
• Anycubic Kobra 2 Neo
• Build volume: ~220 × 220 × 250 mm
Segmentation
Helmet must be split into printable parts:
• Face section
• Dome / crown
• Rear section (battery + fans)
• Side panels (if needed)
• Rear hatch
• Coin-slot screw
Seams should:
• Follow panel lines
• Be hidden after finishing
• Allow structural reinforcement
MATERIAL & PRINT INTENT
Prototype
• PLA+
Final
• PETG recommended
Print guidelines
• Wall thickness: ≥ 3 perimeters
• Infill: 10–15% gyroid
• Designed to avoid excessive supports
OPTIONAL DELIVERABLES (IF TIME ALLOWS)
• Visor test-fit ring STL
• Fan test mount STL
• Battery fit gauge
• Padding placement guide
SUCCESS CRITERIA
Helmet must:
• Fit user comfortably for multi-hour wear
• Accept thick motorcycle padding
• Maintain visor clarity
• Provide fresh airflow
• Allow battery swap without tools
• Print successfully on consumer FDM printer
• Match supplied concept art
- No painting needed; I will handle that myself.
Ideal Skills and Experience:
- Experience in designing helmets for 3D printers
Project Goal
Design a wearable, 3D-printable sci-fi helmet based on supplied concept art, optimized for:
• Long-duration cosplay wear
• Active airflow
• Thick motorcycle helmet padding
• Rear-mounted power system
• Anycubic Kobra 2 Neo print constraints
USER ANTHROPOMETRICS
• Head circumference: 22.25 in / 565 mm
• Target padding clearance: 15–20 mm
• Helmet internal allowance: Sized for motorcycle helmet padding (multi-density foam)
Internal clearance requirements (minimum)
Crown 20mm
Temples 15mm
Back of Head 18mm-20mm
Cheeks ~15mm
Brow - Forehead ~15mm
VISOR SYSTEM
• Visor source:
JT 23262 Elite Prime Single Goggles (paintball visor)
• Design approach: Helmet geometry conforms to visor, not vice versa
Visor mount requirements
• Internal visor lip: 3–4 mm
• Light-blocking overlap (no internal glow bleed)
• Secure retention (screw or clip-based)
• Visor removable without destroying helmet
SHELL CONSTRUCTION
Shell thickness
• 3.2 mm nominal
• ±0.3 mm tolerance acceptable
Helmet type
• Fixed shell
• No hinges or face opening
Exterior style
• Aggressive, intimidating
• Predator-inspired helmet silhouette
• Sleeker, less bulky than Halo MJOLNIR
• Rear mass intentional (fans + battery)
AIRFLOW SYSTEM
Fans
• Quantity: 2
• Type: USB blower fans
• Size: 50 × 50 × 15 mm
Fan placement
• Both fans housed in rear helmet volume
• Vibration-isolated mounts
• Fans not directly adjacent to padding
⸻
Airflow routing (CRITICAL)
Fan A — Anti-fog visor airflow
• Duct from rear → visor interior
• Exit slit positioned to blow across visor surface
• Avoid direct airflow into eyes
Fan B — Breathing airflow
• Duct from rear → mouth/chin area
• Slight downward angle
• Designed to reduce CO₂ buildup
Ducts must be:
• Integrated into shell geometry
• Smooth internal curves (no sharp corners)
• Sealed (no air leaks into padding foam)
POWER SYSTEM
Battery
• Dimensions:
2.7” × 2.75” × 0.9”
≈ 69 × 70 × 23 mm
• Type: USB power bank
Battery location
• Rear of helmet
• Dedicated rigid pocket
• Padding-isolated
• Heat-isolated from head
Battery access
• internal hatch
• User-accessible without tools
FASTENERS — BATTERY HATCH
Coin-slot screw
• 3D printable
• Flush with helmet surface
• Coin-compatible (penny / dime)
• Captive design (cannot fall out)
• Threaded into printed boss or embedded nut
Design intent:
• Stealth exterior
• Convention-friendly battery swaps
ELECTRONICS & WIRING
Switch
• Inline power switch
• Mounted internally near rear / neck edge
• Reachable while wearing helmet
• Visually hidden
Wiring
• Integrated wire channels
• Strain relief at:
• Fan connections
• Battery output
• No loose cables inside helmet
PADDING SYSTEM
• Padding system similar to motorcycle helmet padding
• Thick, removable, washable pads
• Velcro-compatible interior surfaces
• No interference with airflow ducts
• Padding must not block fan outlets
PRINTING CONSTRAINTS
Printer
• Anycubic Kobra 2 Neo
• Build volume: ~220 × 220 × 250 mm
Segmentation
Helmet must be split into printable parts:
• Face section
• Dome / crown
• Rear section (battery + fans)
• Side panels (if needed)
• Rear hatch
• Coin-slot screw
Seams should:
• Follow panel lines
• Be hidden after finishing
• Allow structural reinforcement
MATERIAL & PRINT INTENT
Prototype
• PLA+
Final
• PETG recommended
Print guidelines
• Wall thickness: ≥ 3 perimeters
• Infill: 10–15% gyroid
• Designed to avoid excessive supports
OPTIONAL DELIVERABLES (IF TIME ALLOWS)
• Visor test-fit ring STL
• Fan test mount STL
• Battery fit gauge
• Padding placement guide
SUCCESS CRITERIA
Helmet must:
• Fit user comfortably for multi-hour wear
• Accept thick motorcycle padding
• Maintain visor clarity
• Provide fresh airflow
• Allow battery swap without tools
• Print successfully on consumer FDM printer
• Match supplied concept art
- No painting needed; I will handle that myself.