How to make your very own Star Wars shore trooper helmet

If you’ve clicked on this blog post then it’s obvious that you’re a big Star Wars fan! Well, we’re not here to disappoint you. Today we will show you how to make your very own Star Wars shore trooper helmet! This involves a lot of 3D printing so we suggest that you buy a 3D printer as it is going to be useful for a lot of other projects too! Read more to find out how it is made!


Products needed for this DIY project:

1.      Fusion 360

2.      3D printer

3.      Sanding machine

4.      Bonding paste

5.      Activator and glue

6.      Filler primer

7.      Paint

8.      Weathering wash

9.      Matte clear coat

10.   Plexiglass

11.   Window tint

12.   Heat gun


Let’s get started with our DIY project!


Step 1:

The first step of making your Star Wars shore trooper helmet is to make a 3D model of it in Fusion 360. For this, you need to find two images: one of the front part of the helmet and one of the side of the helmet. Import these images into your software and start tracing out all the details. How accurate you are with tracing out your helmet will determine how accurate the final helmet turns out. After the model is ready, cut it into several pieces to prepare it for 3D printing. The 3D printing process could take several hours or even days so while it’s going on you can binge-watch your favorite Star Wars movies!

Step 2:

Once all the parts have been 3D printed, you need to remove the support material from the pieces carefully using a sharp knife. Then, sand all the pieces down to make them smoother. Remember that the flatter your edges are, the smoother the seam is going to look when you attach the parts.

Step 3:

Once all the parts have been sanded it’s time to glue them together. For this, you could spray on some activator on the edge of one part and put glue on the edge of the other part to glue them together. When they touch, they will get locked together almost instantly. Repeat this process for all the parts until you have the basic structure of your helmet ready.

Step 4:

To fill in the gaps between the seams where two parts were glued together, we will be using a bonding paste that is made by mixing parts of hardener with parts of putty. Apply this on the seams wherever you think that the gaps are too apparent. Then sand down the full helmet with a sanding machine. Repeat the whole process of applying the bonding paste and sanding the helmet down till you’re fully satisfied with how your helmet is looking. You can even spray on some filler primer and sand the helmet down as an additional step to give your helmet an even smoother finish.

Remember to wear a respirator when you’re doing this process because this is something you don’t want to be inhaling.

Step 5:

Next, it’s time to paint our mask. The original Star Wars shore trooper helmet is a shade of yellow. You could stick to this color or paint it something else, the choice is yours! You could airbrush it or use spray paint. You also need to add in all the detail pieces which will be painted black so after the yellow paint has dried you can stick the details on too.

Step 6:

Now it’s time to give the Star Wars shore trooper helmet a weathered look. For this, we will be using a burnt umber wash mixed with a lot of water. Alternatively, you could even use a black wash for this. Smear it over the whole helmet and then wipe it off with a wet paper towel so that it just gives the helmet a subtle weathered effect. After this is done, you can go over the edges with a brush and some black paint to enhance all the details. Spray the whole helmet with a few coats of matte clear coat to protect the paint by preventing it from chipping off.

Step 7:

It’s finally time to make the visor. For this, you can trace the gap that you’ve left for the visor on the helmet and cut a piece of plexiglass slightly larger than your measurements. Then using a heat gun, bend the plexiglass to fit the curve of the helmet. You can then cut some window tint which will be stuck on the plexiglass. Once this is done, apply some epoxy or glue to the inside of the helmet and glue this visor on firmly.

Your Star Wars shore trooper helmet is now complete! Show this off to your friends and family who are Star Wars fans to see the amazement on their faces! We’re sure that you’re never going to take this helmet off after you’ve made it. Enjoy your latest creation!

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