Xenoblade Rex Helmet and Harpoon Armband

thingiverse

My youngest son wants to be Rex from Zenoblade for Halloween. This is edging its way toward a complete costume... We worked up the helmet, and the harpoon armband. Print the harpoon solid, tip pointed down with about 75 to 100 layers of support material. Print the armband with spiral vase, and at least one bottom layer for adhesion. If you're using Repetier/Slic3r, deselect all Quality settings under Layers & Perimeters. I printed using a delta printer. If you have a standard cartesian printer, you may want to use a raft or brim to keep it from coming loose. There are holes to bind to your arm with velcro bands. I updated the armband to allow some flex if you're having trouble inserting the harpoon. It also seems to improve the quality of the print by eliminating internal walls on the spiral print. The faceplate, sideplate and insert can be printed solid. I made the helmet with white glue & water paper mache over a balloon. Cut newspaper strips about 1.25 inches thick. The first layer is just wet paper. That allows the balloon to separate from the paper when dried. I applied about 6 layers, and left it to dry over night. I attached the face and side plates with a glue gun. Cover the helmet body with paint or colored duct tape. This is still in progress. So, I may add more pieces as we get closer to Halloween. Added Thigh Patch. Printed with 2 walls and 2 layers top and bottom. Infill is light 10% to 15%. Patches can be stitched directly to pants thru the holes. Just print 2 smaller copies for the lapel patches. Added Rex's collar and hanger for the helmet. My son pointed out that Rex doesn't actually wear the helmet... It hinges off the backside of his collar, and looks cool in cartoons, but would be miserable in real life. A hinge would have the helmet smacking him in the back of the head. So, decided to hang the helmet backpack-style from a shoulder mounted clip. I used some trellis material (you can find it in the construction section and Home Depot for about $3.50), spread the wire rails to fit comfortably over the head head. Bent it into a shape to clip onto the rim of the helmet, curve over the shoulders, and added rings to the front to loop a belt thru and hold it all in place during furious trick-or-treating. I duct taped a foam collar and shoulder pads. It required a couple of modeling sessions with my 12 year old to get the shape right. But, he says it's comfortable with no wire poking him. I included a picture of the trellis material so you'd know what to look for. (Man... I spend too much time on their Halloween costumes.)