If you’re a loyal Star Wars fan, you won’t want to miss this next helmet. Darth Vader is one of the most iconic characters in this saga. Part cyborg and part human, he’s kept alive only by his intricate robotic suit, fully equipped with a breathing apparatus and electronic limbs. Darth Vader is a fascinating character who was once a heroic Jedi Knight. However, he was seduced by the dark side of the Force and became a villain. With this model, you can join the dark side, too.

The helmet is divided into 38 pieces, so you’ll need to assemble the helmet after printing. Every piece has alignment holes to help with the process before gluing the parts together but, as the designer highlights, if you plan on wearing it, don’t glue the back parts (the FaceR00, FaceR10, FaceL00, and FaceL10 pieces) to the rest. They should only be glued to each other. The designer provides additional assembly instructions on the Printables page.

• Who designed it? lecter
• How printable/popular is it? With over 1,400 downloads and 4 shared makes, we can say that this helmet has its fair share of fans.
• Where to find it? Printables

Marvel’s Avengers have become quite popular thanks to a string of successful films, so how can we miss this next model? Iron Man is one of the most beloved superheroes in the Marvel universe. When Tony Stark wears his iconic red armor, he instantly transforms into the famous hero. With this helmet, you can also become Iron Man.

There are different versions of the Iron Man helmet available for cosplay. This one is Mk3 from Iron Man I, but you can find other models on the designer’s page. To print this helmet, consider using a brim since the pieces are small and can easily detach from the build plate. You’ll also need supports and a 0.16-mm layer height.

The helmet prints in separate pieces, which attach with glue and are then soldered together for a secure fit. The creator recommends printing with a sandable matte filament for best results.

• Who designed it? Official3D
• How printable/popular is it? Over 3,200 people have downloaded this fantastic helmet and 7 of them have published their beautiful makes.
• Where to find it? Printables

Get the Look

Iron Man 3D Print: The Most Amazing Cosplay Props

Remaining in the Avengers universe, another famous character that’s great for cosplay is Captain America. He possesses superhuman strength and uses an indestructible shield as a weapon. Plus, Captain America is considered a symbol of American values, such as freedom, democracy, and justice.

With this model, you can take a dose of “Super-Soldier” serum, and become a real-life superhero. The helmet prints in two pieces, which should then be glued together with epoxy. You can then paint the outside for a realistic look. The creator added a little bit of foam on the inside and a strap around the chin for a comfortable fit.

• Who designed it? Smartdagger
• How printable/popular is it? With over 34,000 downloads and 25 makes, we can say that this character is pretty popular!
• Where to find it? Thingiverse

If you’re team X-Men instead of Avengers, you’ll love this next helmet. Magneto is a powerful mutant that can generate and control magnetic fields. While he’s usually portrayed as a villain in the X-Men series, he was originally a hero defending people’s rights.

Magneto has a cool look, and his helmet is no exception. The designer provided the helmet as a single STL file, although they recommend cutting it into separate pieces for your specific printer. They also suggest printing with PLA and using a soldering iron to carefully attach the pieces together after printing.

• Who designed it? Landru
• How printable/popular is it? With over 23,000 downloads, 17 makes, and 4 remixes, this design is quite appreciated by the community.
• Where to find it? Thingiverse

Electronic music fans will instantly recognize this next design. If you’re more into music than comics, Daft Punk may be your cosplay of choice. This musical duo rose to fame in the ’90s for their unique, danceable tunes and memorable stage shows.

The model is divided into parts to be easier to print. The pieces come together with the help of some joints. For a realistic look, you should prepare to paint the helmet. Or, if you have a multicolor 3D printer, you’ll be able to obtain a realistic look without post-processing.

• Who designed it? mautilio
• How printable/popular is it? With almost 16,500 views and over 650 downloads, plenty of Daft Punk fans are firing up their 3D printers.
• Where to find it? MyMiniFactory

Now, let’s take a look at a design for all you sci-fi fans out there. Starring Matt Damon, The Martian is an iconic film set in space. The protagonist is a stranded astronaut who has to adapt to the difficult conditions of life on Mars.

The creator designed this Martian helmet after watching the film many times. They optimized the design for 3D printing by creating large letters that your machine can easily print. The creator also suggests using PETG, as it’s easier to work with.

If you want a realistic look, you’ll need some paint. When assembling the helmet, you should try hiding the seam with a mix of glue or epoxy and talc, as suggested by a maker on the RPF forum. Printing it at a 0.15-mm layer height will give you a smooth and beautiful surface.

• Who designed it? Empiricus
• How printable/popular is it? Almost 1,500 people have downloaded this helmet, and one maker has shared their beautiful make.
• Where to find it? Printables

Staying in outer space, let’s talk about Doom. Doom is one of the oldest video games around, set on the moons of Mars and in Hell. Created in 1993, this action-packed video game has enjoyed pretty good success over the years and has been turned into a TV series, comic books, and books. The protagonist is a Space Marine whose look you can try out for your next cosplay convention, thanks to this cool, wearable helmet.

You’ll need a little bit of paint if you want a realistic look, so it’s recommended to print in military green and add the details with a brush afterward.

• Who designed it? Jace1969
• How printable/popular is it? Over 26,000 people have downloaded this model and 12 of them have published their makes.
• Where to find it? Printables, Thingiverse

Here is another cosplay helmet that video game fans will love. Halo is a popular sci-fi military video game, originally released in 2001. The game is set in the 26th century and follows the story of Master Chief, a supersoldier who’s half-cybernetic, half-human, and fighting against alien races. From the original video game, Halo has gained popularity as a book series, comic series, feature film, and more.

If you feel ready to fight aliens, printing this helmet for your cosplay costume is a must! The designer has modeled different sizes to fit adults and children. The helmet prints in 20 pieces, some of which require supports. After assembling, you’ll also have the space to add some LED lights and create your own visor. The result is worth the time! You’ll find detailed project instructions on Hackaday.

• Who designed it? big_red_frog
• How printable/popular is it? This is the most popular model on our list. Over 90,000 people have downloaded it and 144 have published their makes! Plus, there are 17 remixes.
• Where to find it? Thingiverse

The Rocketeer is a masked comic book character created in 1982. The story begins in 1938 when pilot Cliff Secord discovers a stolen rocket pack. He eventually goes on to use this as a weapon to fight crime.

With this model, you can travel back in time and become the Rocketeer yourself. To print the helmet, you’ll want to use supports and a 0.2-mm layer height. Also, you’ll need a larger print bed like the one on the Creality CR-10, which is about 300 x 300 mm in size. The helmet prints in five pieces, which you’ll then assemble together.

• Who designed it? drokle (remixed from davypenn02)
• How printable/popular is it? Over 5,000 people have downloaded this model and 11 of them have published their makes.
• Where to find it? Thingiverse