How To Add A Visor To A 3D Printed Helmet | Easy Method #3dprinting

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In this comprehensive article, you will learn an easy method to add a visor to a 3D printed helmet. The step-by-step guide, presented by VaderDad Builds in a video, will walk you through each stage of the process, providing you with valuable insights and practical tips. This method is not only cost-effective but also versatile, as it can be applied to a variety of cosplay helmets, including those inspired by Star Wars and Marvel. From selecting the right materials to seamlessly integrating the visor into your helmet, this tutorial will equip you with the necessary knowledge to elevate your helmet to the next level. Subscribe for more 3D printing tutorials and Star Wars builds using free STL files.

Let’s dive into the details of this tutorial. The lens of the visor is made up of a clear plastic PET sheet, which is easy to shape and bend to accommodate any curves in your helmet. Additionally, you will need to tint the plastic for added effect, using a roll of tail light vinyl film. Lighter colors are recommended for better visibility from the inside. By cutting a paper template and then tracing and cutting out a similarly-sized rectangle from the plastic sheet and tinted film, you are on your way to constructing the visor. Take your time to remove any bubbles, dry the visor, and then attach it to the helmet using Velcro or hot glue. Ultimately, you will have a finished helmet that is both functional and visually appealing.

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Table of Contents

Choosing the Right Materials

When adding a visor to a 3D printed helmet, it is important to choose the right materials to ensure a successful outcome. Here are the materials you will need:

Clear plastic PET sheet: This sheet will serve as the base for the visor. It is recommended to use a 12 x 12 inch sheet with a thickness of .02 or .04 inches, depending on your preferences for flexibility or sturdiness.
Tinted vinyl film: This film will provide the tint for the visor. It comes in a variety of colors, so you can choose one that matches your helmet design. A 12 x 48 inch roll should be sufficient.
Spray bottle with water: This will be used to wet the plastic sheet to aid in the application of the tinted film.
Paper towels: These will be used to remove excess water during the process.
Scissors: These will be used to cut out the visor shape from the plastic sheet and the tinted film.
Plastic squeegee: This tool will help push out any bubbles and ensure smooth application of the tinted film.

By gathering these materials beforehand, you will be well-prepared to add a visor to your 3D printed helmet.

Cutting the Materials

To begin the process, you will need to cut the materials to the appropriate size and shape. Here are the steps to follow:

Create a paper template for the visor shape: Start by cutting a sheet of paper to get the basic shape of the visor. The template does not need to be perfect, but it should be larger than the opening of the helmet.
Place the template on the plastic sheet and cut out a larger rectangle: Position the paper template on the plastic sheet and carefully cut out a rectangle that is larger than the template. This will allow for adjustments during the attachment process.
Cut out the same size rectangle from the tinted film: Use the same template to cut out a rectangle from the tinted film. This will serve as the tint for the visor.
Remove the protective film from one side of the plastic sheet: Peel off the protective film from one side of the plastic sheet to prepare it for the attachment process.
Spray the plastic sheet with water: Using the spray bottle, lightly mist the plastic sheet with water. This will help the tinted film adhere smoothly to the plastic.
Remove the protective film from the adhesive side of the tinted vinyl: Peel off the protective film from the adhesive side of the tinted vinyl. This will expose the sticky surface that will adhere to the plastic sheet.
Place the tinted vinyl on the plastic sheet: Carefully place the tinted vinyl on top of the sprayed plastic sheet, ensuring that it aligns with the cut-out shape. The adhesive side should be facing the plastic sheet.
Use the squeegee to push out any bubbles: Starting from the center and working your way outwards, use the plastic squeegee to firmly press the tinted vinyl onto the plastic sheet. This will help remove any bubbles and ensure a smooth surface.
Use paper towels to remove excess water: Gently pat the surface of the visor with paper towels to remove any excess water. This will help speed up the drying process.
Let it dry for about 1 hour: Allow the visor to dry for approximately 1 hour before proceeding to the next step. This will ensure that the adhesive has fully bonded and the visor is ready for attachment.
Cut out the visor using the paper template: Once the visor has dried, place the paper template back on top of the visor and use it as a guide to cut out the final shape of the visor. Make any necessary adjustments to ensure it fits properly in the helmet opening.

By following these steps, you will have successfully prepared the materials and cut out the visor for your 3D printed helmet.

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Attaching the Visor

After cutting the visor to the desired shape, it is time to attach it to the helmet. Here is a step-by-step guide:

Decide whether to use hot glue or Velcro: Depending on your preferences and the design of your helmet, you can choose to attach the visor using either hot glue or Velcro. Hot glue offers a permanent solution, while Velcro allows for easy removal and reattachment.
Cut Velcro strips: If you decide to use Velcro, start by cutting appropriate lengths of Velcro strips. These strips should be long enough to fit across the opening of the helmet.
Attach Velcro Hooks to the helmet opening: Peel off the adhesive backing from the Velcro Hooks, which are the rough side of the Velcro, and carefully attach them to the inner side of the helmet opening. Make sure they are evenly spaced and securely fastened.
Attach Velcro Loops to the Hooks: Peel off the adhesive backing from the Velcro Loops, which are the soft side of the Velcro, and attach them to the Hooks. This will create a secure connection for the visor to attach to.
Remove the protective film from the plastic side of the visor: Peel off the protective film from the plastic side of the visor, exposing the adhesive surface.
Place the visor plastic side down on the helmet: With the adhesive side facing down, carefully position the visor on the helmet opening. Make sure it aligns properly and covers the desired area.
Press down to ensure adhesive sticks: Apply firm pressure to the visor, pressing it down onto the Velcro Hooks and Loops. This will ensure a strong and secure bond between the visor and the helmet.
Remove the protective film from the tint: Finally, peel off the protective film from the tinted side of the visor. This will reveal the tinted surface and complete the attachment process.

By following these steps, you will have successfully attached the visor to your 3D printed helmet using either hot glue or Velcro.

Tips and Tricks

When adding a visor to a 3D printed helmet, here are some tips and tricks to keep in mind:

Choose lighter colors for better visibility: When selecting a tinted film for your visor, opt for lighter colors. Darker tints may appear similar from the outside when the helmet is closed, but they can significantly reduce visibility from the inside.
Cut the visor larger than the opening to allow for adjustments: It is recommended to cut the visor slightly larger than the opening of the helmet. This will allow for adjustments and ensure a proper fit.
Use glue for better adhesion of Velcro: If you choose to attach the visor with Velcro, consider using glue to secure the Velcro strips to the helmet. This will provide additional stability and prevent the Velcro from coming loose over time.
Form the visor to the curve of the helmet before pressing down: Before firmly pressing down the visor onto the helmet, take the time to shape it to fit the curve of the helmet. This will help achieve a seamless and professional appearance.
Push out any remaining bubbles with the squeegee: Even after using the squeegee during the attachment process, there may still be some stubborn bubbles trapped between the visor and the plastic sheet. Take the time to go over the visor again with the squeegee, ensuring all bubbles are eliminated.
Use paper towels to remove excess water during the drying process: As the visor dries, there may be excess water that accumulates on the surface. Use paper towels to carefully remove this excess water, as it can hinder the drying process and affect the adhesion of the tinted film.

By keeping these tips and tricks in mind, you can ensure a successful and professional-looking visor attachment for your 3D printed helmet.

Tutorial Video By VaderDad Builds

For further visual guidance and demonstration of the visor addition process, you can refer to the tutorial video by VaderDad Builds. This video provides an introduction to the process, a step-by-step guide, and visual demonstrations of each stage. Additionally, the video offers tips and tricks to enhance your visor attachment experience.

By following along with this tutorial video, you can gain additional insight and guidance to successfully add a visor to your 3D printed helmet.

Benefits of Adding a Visor to a 3D Printed Helmet

There are several benefits to adding a visor to a 3D printed helmet. Here are a few:

Enhances the appearance of the helmet: By adding a visor, you can instantly enhance the overall look and feel of your 3D printed helmet. The visor adds a touch of realism and can bring your helmet design to life.
Provides protection to the wearer’s eyes: A properly attached and tinted visor can provide protection to the wearer’s eyes from harsh sunlight, debris, or other potential hazards. This is especially important in cosplay situations or outdoor events.
Allows for customization with different tints and colors: With a variety of tinted films available, adding a visor to your helmet allows for endless customization options. You can choose different tints and colors to match your helmet design or personal preference.
Compatible with various cosplay helmet designs: The method of adding a visor to a 3D printed helmet described in this article is versatile and can be applied to various cosplay helmet designs, including popular ones like Star Wars helmets, Marvel helmets, and many others. It offers a cost-effective and easy solution to achieving a professional-looking visor attachment.

By adding a visor to your 3D printed helmet, you can enjoy these benefits and enhance both the appearance and functionality of your helmet.

Different Types of 3D Printed Helmets

There is a wide range of 3D printed helmets available for cosplay and other purposes. Here are some popular types:

Scout trooper helmet: This helmet is commonly associated with the Star Wars universe and is known for its sleek and futuristic design. Adding a visor to a scout trooper helmet can further enhance its authenticity.
Star Wars helmets: There are various other Star Wars helmets that can be 3D printed and customized, such as Darth Vader, Stormtrooper, Boba Fett, and Mandalorian helmets. Adding a visor to these helmets can make them even more visually striking.
Marvel helmets: With the popularity of superheroes and the Marvel Cinematic Universe, there are many 3D printed Marvel helmets available for cosplay. From Iron Man to Captain America to Black Panther, these helmets can be further enhanced with the addition of a visor.
Cosplay helmets: In addition to specific character helmets, there are also many generic cosplay helmets that can be 3D printed. These helmets can be customized to match any desired theme or design, and a visor can be added to elevate their overall appearance.
Other 3D printed helmet designs: Beyond Star Wars and Marvel, there are countless other 3D printed helmet designs available. Whether you are interested in sci-fi, fantasy, video game, or any other genre, chances are there is a 3D printed helmet design that suits your preferences.

By exploring these different types of 3D printed helmets, you can find inspiration for your own projects and further personalize your helmet with a visor attachment.

Common Challenges When Adding a Visor

While adding a visor to a 3D printed helmet is a relatively straightforward process, there are a few common challenges that may arise. Here are some of them:

Matching the visor shape to the helmet opening: Ensuring that the cut-out shape of the visor matches the opening of the helmet can be tricky. It is important to carefully measure and cut the visor to achieve a proper fit.
Ensuring proper adhesion of the visor: The adhesive used to attach the visor can sometimes be less effective, especially when exposed to moisture or movement. It is recommended to use additional measures like glue or reinforcement to ensure the visor stays securely attached.
Avoiding bubbles and wrinkles in the tinted film: When applying the tinted film to the plastic sheet, it is important to take care to prevent the formation of bubbles or wrinkles. Using the squeegee and working slowly and methodically can help avoid these issues.
Cutting the visor too small or too large: Cutting the visor too small can result in an incomplete coverage of the helmet opening, while cutting it too large can make it difficult to properly attach the visor. It is advisable to cut the visor slightly larger than the opening to allow for adjustments.

By being aware of these common challenges and taking the necessary precautions, you can overcome them and successfully add a visor to your 3D printed helmet.

Testing and Adjusting the Visor

Once the visor is attached to your helmet, it is important to test its functionality and make any necessary adjustments. Here is what you should do:

Wear the helmet and assess visibility: Put on the helmet and assess the visibility provided by the visor. Check whether there are any obstructions or distortions that affect your field of vision.
Make any necessary adjustments to the size or positioning of the visor: If you find any issues with visibility or fit, make the necessary adjustments to the size or positioning of the visor. This may involve trimming the visor or reattaching it with different adhesive methods.
Ensure the visor is secure and does not obstruct vision: Once you have made any adjustments, ensure that the visor is securely attached to the helmet and does not obstruct your vision in any way. This will ensure optimal comfort and safety while wearing the helmet.

By thoroughly testing and adjusting the visor, you can ensure that it performs as intended and enhances your overall helmet-wearing experience.

Conclusion

Adding a visor to a 3D printed helmet is a straightforward and cost-effective method to enhance both the appearance and functionality of your helmet. By choosing the right materials, cutting them to the appropriate size and shape, and carefully attaching the visor, you can achieve a professional-looking result. Whether you are working on a scout trooper helmet, a Star Wars helmet, a Marvel helmet, or any other 3D printed helmet design, this easy-to-follow DIY tutorial will guide you through the process. With the addition of a visor, you can enjoy improved aesthetics and protection for your helmet, while also having the opportunity to customize it with various tints and colors. So, gather the necessary materials, follow the step-by-step process, and take your helmet to the next level with a visor attachment.

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