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Advanced Cosplay Armor & Wearable Props from 3D Printing

Print armor segments, fit them to your body, post-process, and wear confidently

Difficulty
Advanced
Print Time 40-80 hours per suit
Category Functional Prints

Materials Needed

  • 2-4kg PLA filament (multiple colors)
  • EVA foam for padding
  • Contact cement or flexible adhesive
  • Sandpaper (120, 220 grit)
  • Spray primer and paint

Cosplay armor printed in segments is lighter than traditional methods, custom-fitted, and surprisingly durable. This guide covers the complete process from design to wearing.

Design and Sizing

Before printing:

  1. Choose your character and reference armor design
  2. Download a model from MyMiniFactory, Thingiverse, or commission a custom design
  3. Scale the model to your body measurements
    • Print a small test piece (5×5cm) to verify fit and feel
    • Adjust scale; most models default to average sizing
  4. Break the model into segments that fit your printer’s bed (typically 220×220mm)
    • Armor should segment at natural breaks (shoulder plates, chest panels, arm guards)
    • Plan for overlap when assembling

Critical measurement:

  • Shoulder width: 40-50cm typical
  • Chest circumference: 90-110cm typical
  • Arm length (shoulder to wrist): 60-70cm typical

Reference your actual body, not the character design.

Printing Armor Segments

Settings:

  • Layer height: 0.2mm (balance of strength and print time)
  • Infill: 15-20% (lighter than solid, sufficient for armor)
  • Supports: Enable tree supports; armor has many overhangs
  • Speed: 60-80mm/s (slower = stronger prints)
  • Material: PLA in your color choice

Print time estimate:

  • Average armor suit (chest, arms, legs): 40-80 hours total
  • Budget: 2-4kg filament at $20-25/kg = $40-100 material cost

Organization:

  • Label each segment before printing (mark nozzle position on the file name)
  • Group segments by color to minimize filament changes
  • Print largest segments first to catch design issues early

Post-Processing: The Time-Intensive Step

Printed armor is rough. Finishing takes 2-3x longer than printing.

Sanding (Essential for appearance)

  1. Remove supports: Use pliers to snap off tree supports. Sand remaining material smooth.
  2. 120-grit sandpaper: Sand all surfaces with rough strokes to remove layer lines. Takes 30-60 minutes per large segment.
  3. 220-grit sandpaper: Final sand with light, circular motions for smooth finish.
  4. Wipe dust: Use a damp cloth to remove all sanding dust.

Pro tip: Use a power sander for large flat surfaces. Hand sand curved areas and details.

Filler Primer (Reveals Imperfections)

  1. Spray light coat of filler primer on all segments
  2. Let dry completely (30 minutes)
  3. Examine for gaps, warping, or defects
  4. Sand smooth any imperfections
  5. Repeat primer + sand cycle until surface is smooth

Cost: $15-20 per can, need 2-3 cans per suit

Painting

  1. Base coat: Spray paint in your primary armor color. Two thin coats better than one thick coat.
  2. Detail work: Hand-paint details (trim, scratches, battle damage) with acrylics or spray paint
  3. Weathering: Dry brush darker colors into crevices for depth
  4. Sealant: Matte or gloss clear coat protects paint from handling

Cost: $30-50 in paints per suit

Assembly and Fitting

Connecting Segments

Best method: Flexible adhesive

  1. Use contact cement or flexible epoxy (not super glue, which is rigid and brittle)
  2. Apply thin coat to both surfaces
  3. Hold together for 60 seconds
  4. Allow 24 hours to cure before wearing

Alternative: Velcro straps

  1. Attach adhesive-backed Velcro to segment edges
  2. Allows disassembly for storage and adjustments
  3. More comfortable for extended wear

Fit and Alignment

  1. Put on the armor with segments not yet glued
  2. Check movement: arms should raise 90°, torso should bend slightly
  3. Mark any areas that rub or prevent movement
  4. Sand or carefully trim problem areas
  5. Adjust attachment points (higher, lower, tighter, looser)
  6. Once fit is correct, glue permanently

Critical fit check: Walk, raise arms, sit down. If you can’t move, redesign is needed.

Wearability

Add padding to segments that contact skin:

  1. Glue EVA foam or closed-cell foam padding inside armor
  2. Use contact cement; it bonds plastic and foam reliably
  3. Pad shoulders, chest sides, and arm insides

For large armor pieces, add straps:

  1. Attach velcro or elastic straps to the inside
  2. These distribute weight across your shoulders and torso
  3. Prevents pinching and sliding

Durability Expectations

Print quality: PLA at 15-20% infill is surprisingly durable. Takes impact without shattering.

Finish quality: Paint will chip with heavy wear. Touch-up paint ($5) restores it. Sealant helps.

Lifespan: Armor typically survives 5-10 convention uses before needing repainting. With care, 2+ years.

Cost Breakdown (Per Suit)

  • Filament: $40-100
  • Primer/paint: $50-70
  • Padding and adhesive: $20-30
  • Straps and hardware: $15-20
  • Total: $125-220 (vs. $300+ for professional cosplay armor)

Common Mistakes

Printing at 0.3mm layer height: Looks rough, requires extensive sanding. Use 0.2mm.

Skipping primer: Spray paint doesn’t hide layer lines. Primer reveals and fills them.

Over-infilling: 30-40% infill makes armor heavy and slower to print. 15-20% is plenty.

Poor fit before assembly: Glue armor that doesn’t fit, and you’re stuck. Verify fit first.

Ignoring weight distribution: Large armor pieces need internal straps or weight concentrates at the center, pulling downward. Support from shoulders.

Printed cosplay armor is achievable, affordable, and surprisingly professional-looking. The time investment is real—expect 40+ hours of printing and finishing—but the result is custom, lightweight, and uniquely yours.