3d Printing for Cosplay Part 1

2:20 PM

Alright, I've had some people ask me about 3d printing for cosplay.  I am not what I would consider an expert on the topic, but I do know a decent amount about 3d printers and printing in the home or on a small scale.  So, I'm going to do my best to cover it.  This will not be an all encompassing thing, but I'll tell you what I can and the post will also serve as a decent segue into my 3d printed props for Wilhelmina.





     3d printing has a lot of great applications for cosplay.  This is especially true for those of us struggling with carving out blocks of EVA or expanding foam and the like.  All it takes is finding or making a model of the prop you need, optimizing it for printing, printing it out, and finishing the print for painting and detailing.  The added benefit of printing a prop is you have a whole new range of materials to work with such as ABS plastic, Nylon, Wood/Stone amalgams, flexible filament, and even things like bronze-fill which is incredible.  The big differences are in work flow and, of course, tools and equipment.

     Let's start with tools and equipment.  

     You will need a printer, obviously.  These are often pricey and generally out of most people's budgets.  Most new and ready to print consumer level printers (ones that don't require any assembly) will run you between $1200 and $6000 depending on the type of printer you want, the company, and various features.  For an example, here is a range of available printers and their price points.  On the low cost end, the Lulzbot Mini is a great little machine with a price of $1250.  For midrange pricing, we have the printer most people think about when they think 3d printing, the Makerbot Replicator for $2899.  A lot of people swear by the Replicator, but I have always found it to be a bit of a let down at the price.  On the high end, we have the AirwolfAxiom at just under $5000. These are not suggestions, simply giving you and idea of the possible price ranges.  There are alternatives to these out-of-box printers that result in cheaper costs. These are more likely to require some degree of knowledge on the machine and electronics front, however. You can ALWAYS find printers available on ebay. While many of these will have very little wrong with them, there will likely be something you need to fix or replace. Usually the seller will mention what is wrong with the printer. But if you are careful and honest with yourself about your ability, you can get a great preassembled printer for a veritable steal. Another option is printer kits. These are fabulous for those with some tech background, or simply a do-it-yourself mentality. These require some assembly and often wiring, but if you have the combination of knowledge, patience, and a little bit of bravery you can get a great printer for under $500.
     When it comes to finding the right printer for you, that is going to take some research. I can't do it for you, but I can give you advice. There are a great deal of things you will want to consider when shopping for your printer. Obviously budget is going to be a big deal, but it doesn't stop there. Here are a few things to think about-

  • Type of material. There is a wide range of materials available and all have their own properties. The most common you will see used are PLA and ABS plastic. Both melt at a reasonably low temperature (about 150c to 260c, generally) and have a decent strength. They are cheap and readily available.
  • Print resolution. Simply put, this is the quality of print. The lower the resolution, the thinner the layers of material, and the higher the quality of print. The difference in resolution comes at the cost of amount of material used and time to finish a print. Most consumer printers seem to print between 100 microns (.1mm) and 300 microns (.3mm). Though many are coming on the market with a high resolution end of 50 and even 20 microns. Keep in mind, you will be paying for that better print resolution.
  • Print area. This is pretty clear. The larger the print area, the larger the possible print. Most consumer printers seem to have an average of about an 8 inch cube with some much smaller and some a decent amount larger.
  • Your print environment. This can be a pretty big factor. For example: If you are thinking of printing inside your home, you will likely want something that can print relatively quiet and the presence of decent climate control inside a living space means an enclosure isn't terribly necessary. However, if you are printing in a garage or workshop you won't necessarily need to worry about sound levels but will be more likely to require an enclosure to help regulate temperature.
  • Type of build platform. Put simply, this is what your print will sit on and adhere to.This can have a pretty big effect on your quality of print and is also highly dependent on the type of material you will use. The most used print beds seem to be aluminum, glass, and ceramic. and ceramic. No matter the material of your build platform, you will most likely need a form of interface to help the print adhere. These can include Kapton tape, PTFE, blue painters tape, an abs slurry, or even simple purple gluestick. What works best will depend on your material and will require some experimentation on your part. One thing I can't encourage enough is a heated platform. This makes a HUGE difference when it comes to quality printing.
  • Connectivity. Is it tethered to your computer via USB? Is it wireless? Does it require the file to be directly loaded to the printer on an SD card? Is there an app for your phone to monitor and control the printer? These are all things to consider and go beyond just preference. Think about your space and your needs when you search for the right printer.
  • Tech/customer support. It is a certain that eventually you will need help of some kind help with your printer. Be this due to damage on shipment, a catastrophically clogged printer head, fried stepper motor, or myriad other things. Having a company with good tech and customer service backing you up during these times can be a huge benefit.
  • Community around the printer. The printing community is, mostly, incredibly talkative an helpful. These things aren't just tools, they are a hobby and as a result, there are tons of people who just can't wait to talk about their trials and triumphs with their printers and printing in general. What's more, communities pop up around individual printer brands and models. This means you will always have a great resource available to help you with potential problems and give advice. Just make sure you check the FAQ of the reddit or forum you are on before you ask. ;)
  • Aesthetics. This is purely up to you and your your preferences. Printers come in the purely functional, unassuming, and even flashy-tokyo-drift kind of printers. If you worry about how a printer will look on your worktable, office, or workshop then you will want to consider this. Keep in mind that looks often come with a price tag and if you want those slick and stylish purple LED strips running that beautifully engraved acrylic enclosure . . . well, you're gonna pay for it.
     To get a sense of what you want, check reviews on places like 3dhubs, Consumer Reports, and Tom's Guide. A good review of available printers can be super helpful in helping you decide what type of printer you need. And don't forget to talk to the printing community for help as well.
     Something I didn't mention above the need to consider how comfortable you are working with machinery and electronics. No matter how you go about it, you WILL be calibrating, troubleshooting, tinkering, fiddling, and even repairing your printer. These things can take a decent amount of abuse, but they are also finely calibrated machines. As a result, if something small goes wrong it can effect the whole machine and even prevent any printing from happening. There are many printers that claim to take the fiddling out of printing, but from my experience this is all chaff. The reality is you WILL end up messing about with your printer to keep it going and insure the best prints. The only difference between so called plug-and-print printers and enthusiast printers is minimal and the cost for these ease-of-use printers is higher. That said, it can make a difference depending on your level of experience and bravery. So, keep that in mind and be prepared for a learning curve, whatever printer you choose. It isn't all gloom and doom on the maintenance front, though. There are crazy amounts of guides and YouTube vids to help you out of any number of jams and even upgrades.

     Now that you have your equipment, let's talk tools and items you will need. These are all easily obtained and often quite cheap. You may already have these in your tool box.
  • Setof metric hex-ball drivers – These will be used for everything from calibration to printer repair as most of your printer will likely be assembled using machine screws with hex heads
  • Precisionscrewdrivers – The parts of your printer that don't use hex screws will use tiny screws like your computer. These are also great for the unconventional use of removing small support material without having to immediately break out your hobby knife.
  • Digitalcaliper – These will be needed for calibration of your printer. There is no other way around it. You WILL need one of these and some extra batteries just in case.
  • Heatand electric resistant tweezers – These are great for a ton of reasons from plucking material gunk from your print head, cleaning up prints, holding parts while repairing, or even simply retrieving screws fallen in a difficult to access area. They don't need to be electrical and heat resistant, but it is nice.
  • NeedleNose Pliers – This are basically needed to take care of the tasks your tweezers are too small or fragile to manage. They are also great for removing relatively stubborn pieces of large support material from your prints.
  • Thinblade metal putty knife – For detaching stubborn prints from your print surface. Be careful not to scratch that surface, though.
  • Flushcutter – You will want one of these for a variety of reasons from snipping filament to cleaning up your print after the fact.
  • HobbyKnife – You will need these to help finish your prints.
  • Toothbrush – Yup . . . a toothbrush. These are unbeatable at cleaning your printhead and extruder assembly from material dust and bits.
  • Acetone – If you are printing in ABS, which you most likely will, you will need this stuff like woah! Not only is it the only way to clean up messy print beds, it also is used to create the amazing ABS juice/goo/slurry/sludge/glue/whatever-you-want-to-call-it. It can even be used to help finish your prints using a careful acetone fume bath.
  • Other stuff you probably will want on hand – glass mason jar (for your abs juice), something to hold your scrap material (deli container, Tupperware, just not a bag), rubber gloves, face mask or even a respirator if you are using material like nylon, scissors, zip ties, gator clips, folding bone, dental mirror, laser thermometer, paint brushes, small LED flashlight, pieces of scrap paper . . . there are more, but you will discover the little things you will need as you go.

     A lot of this stuff you may already have and the stuff you don't is relatively cheap to get when compared to what you already dropped on a printer. You will use all of it at some point and some things very often. You will also find a variety of things by improvisation that you will find indispensable. So, keep an open mind.

     There are alternatives to buying all of these things, though. A great many services are available online that will print out your design for a price and ship it to you – a great choice if you just need a few decent quality prints or prints with exotic materials. Wherever you live there is likely to be a makergroup or makerspace. Check with them to see if they have one and what they charge for a membership or the use of their printer. There are also nifty places like Omaha's DoSpace popping up with different tech available for use that often include 3d printers. And even many libraries have 3d printers available that will often let you print items for a ridiculously low cost. So, just because you can't afford or don't think you will make enough use out of your own printer, there are still many options out there for using these tools for your next cosplay project.


     Okay, I was going to go through other things, but this post got kinda big. I will write up another one going into how I use my 3d printer for props along with tips, tricks, traps, and trip-ups I have discovered when printing cosplay items.

You Might Also Like

0 comments

Popular Posts