How We Finish 3D Printed Cosplay Armor
For years, 3D printing has been one of our primary tools for creating costumes and props. One of the builds where we really refined our finishing process was our Spartan Recluse armor from Halo 5: Guardians.
For this suit, we started with files from Halo 5: Guardians and extensively reworked the models for 3D printing, adding additional details along the way. The armor was printed in PolyLite PLA and assembled before beginning the finishing process.
For this tutorial, we'll walk through how we finished the chest armor, taking it from a raw assembled 3D print to a completed piece ready for cosplay.
This tutorial was originally written for Polymaker and published as part of a feature on our Spartan Recluse build. We’ve adapted and updated it here for the Alpha to Zeta Industries tutorial library.
A quick note: This build was completed several years ago, and some of the specific products and techniques we use today have evolved. However, the overall process of seam filling, surface preparation, sanding, priming, painting, and weathering remains largely the same.
Starting With the Raw Print
Once the individual sections of the chest armor were printed, they were assembled into the complete piece.
At this stage, the layer lines and seams between the different printed sections were still clearly visible.
Raw print assembled
Hiding the Seams
The first problem we tackled was hiding the seams.
For this build, we filled each seam with a mixture of baby powder and cyanoacrylate, or CA, glue. Once the seam was filled, an accelerator was applied to quickly solidify the mixture.
We then sanded the seams until they were flush with the surrounding surface.
Seams filled
Seams filled and sanded
The goal at this stage is to make the individual printed sections begin to look and feel like a single continuous piece.
Smoothing the Print
Next, we covered the entire piece with Smooth-On XTC-3D.
XTC-3D is a two-part epoxy coating that fills a large portion of the visible layer lines while also adding a degree of strength to the print.
Once the epoxy had completely cured, we began the more extensive sanding and surface-preparation process.
For this build, that process had three main parts.
First, we applied Bondo spot putty anywhere that required additional filling.
Once the spot putty dried, we sanded the piece using medium-to-high-grit sandpaper.
Finally, we applied filler primer across the entire piece.
Then we repeated the process.
Fill. Sand. Prime. Repeat.
We continued cycling through these steps until the surface was smoothed to our satisfaction.
After a run of filler primer
This portion of the process can take some time, but it is also where much of the final appearance of the armor is determined. The smoother the surface is before paint, the better the finished piece will look.
Final Wet Sanding
Once the print lines, seams, and other imperfections were filled to our liking, we wet sanded the entire piece up to 1500-grit sandpaper.
This final sanding helped give us an extremely smooth surface and prepared the armor for paint.
Once the wet sanding was complete, the fun part could finally begin.
Adding the Metallic Base Coat
Before applying the primary armor color, we first put down a metallic base coat.
Metallic base coat
Once the metallic paint dried, we covered it with a clear coat.
This metallic layer was an important part of the weathering process. Later, portions of the main color could be intentionally scraped or distressed, allowing the metallic base coat underneath to show through.
The result gives the appearance of paint that has worn away to expose metal underneath.
Final Color and Details
After the metallic base and clear coat had completely dried, we applied the main armor color along with the other desired details.
The final result was a finished chest piece ready for cosplay.
The finished piece
The Finished Result
Finishing 3D printed armor can be a process, but our goal has always been to get the smoothest finish possible on our costumes.
The techniques and materials we use have continued to evolve over the years, but this process worked extremely well for us on the Recluse build and helped establish many of the fundamentals we still use today.
The most important part is taking your time with the surface preparation. Filling seams, removing print lines, sanding, priming, and repeating those steps until you're satisfied with the surface makes a tremendous difference once the final paint is applied.
If you're getting started with cosplay or 3D printed armor, don't be afraid to experiment and find the process that works best for you.
For anyone specifically interested in Halo cosplay, we also highly recommend visiting 405th.com. The 405th Infantry Division is an incredible community of Halo costumers with a huge amount of accumulated knowledge and members who are always willing to help new builders.
A Little History
This finishing process was originally shared with Polymaker in 2019 as part of a feature on our Spartan Recluse build. We've adapted it here as part of the Alpha to Zeta Industries tutorial library so it can continue serving as a resource for other makers and cosplayers.
[Read the original Polymaker feature →Click Here]