"Luke, you switched off your targeting computer, what's wrong?"
“Nothing, I'm alright.”

3D print a custom 8:1 scale replica of the popular toy bricks minifigure X-Wing pilot helmet that Luke Skywalker wore in Star Wars.

Printing Guide

It is recommended to use the print profile I have provided to print the helmet. I also recommend printing on a smooth surface PEI plate to minimize the parting line between the two helmet halves.

An AMS is required for this print, and the main model only requires four colors. You can use any filament colors and brand that you have on hand, but I used:

• eSun PLA+ White
• ZIRO PLA Red
• Sunlu PLA Pure Yellow
• Sunlu Meta PLA Black
• OPTIONAL Sunlu PLA Transparent Yellow for the visor, otherwise solid yellow will work.

NOTE: You may get messages that there is a manifold error with the model. Bambu Studio will attempt to repair them but cannot. This is OK, the part will still print. The model got corrupted somewhere between editing in Blender and Solidworks, and I can't fix it without starting all over.

It takes about 26ish total hours to print the helmet, the front yellow, black, and white striped part, and visor.

Assembly

The helmet is printed in two halves and is glued together. Assembly is pretty straight forward:

1. Test fit the pegs into the holes in the helmet halves. They should fit with just a little friction, but may require filing or sanding.
2. Put 1-2 drops of CA glue (I recommend Bob Smith Industries Maxi-Cure and Insta-set) into each of the four holes on one helmet half and insert the pegs.
3. Wait approximately 60 seconds (or about 5-10 if using Insta-set).
4. On the other helmet half, apply a thin bead of glue in the center of the flat connecting surface and another drop in each hole.
5. Press the two halves together, and hold for about 1-2 minutes (or about 20-30 if using Insta-set). If you have a bar clamp, it is recommended to use one.
6. Put 3-4 drops of glue in the notch in the front of the helmet (see diagram below).
7. Place helmet front (the yellow, black, and white striped part) into the notch, lining up the raised block with the notch.
8. Put the yellow visor into place by lining up the pegs with the holes. It should stay there with friction, otherwise you may glue it.
9. Let sit for about 20-30 minutes before handling again.

That should do it! Enjoy your display piece!