Kids Cosplay - Hollow Knight Mask and Needle

This is a Mask and sword designed for kids (or adults if you resize!)

The Head is cut into 2 pieces and the sword is cut into 4.
A large format printer would be best (350x350mm).

UPDATE: I have added a new version with the helmet split into 6 sections. It should just BARELY fit on a print bed of 235x235mm!

Print settings:
Layer height: .2mm
Infill: 10%-15%
Walls: 2-3 (adding an extra wall increases weight and material cost but you will negate the risk of sanding through the wall when post-processing)
Supports: EVERYWHERE on the Head pieces / NONE on the Sword

I have also included printable alignment pins but you can also use any 5mm dowels. The internal dimensions of the alignment holes are 5mm x 20mm. I would give yourself some wiggle room on the length and shoot for 5mm x 18mm to prevent a gap.

To achieve a smooth surface like in the pictures:
- Sand all parts with 120grit (palm sander) until all heavy layer lines are pretty smooth
- Fill any larger holes or cracks with woodfiller putty
- When dry, use 120grit to sand woodfiller smoot
- Clean and apply 2-3 coats of Auto Body Gray Filler Primer.
- Wait 48 hours and sand with 400grit
- Clean and apply 3-4 LIGHT coats of top coat paint. Waiting a few min in between (or manufacturer recommended recoat time)
- If you goof up, just wait 24-48 hours and sand with 400 grit and re-apply coats

Let me know if you have any problems and I will work things out with you!