Do you have access to a 3D printer and want to show everyone up on Halloween this year? 3D printers are taking cosplaying to a whole new level with things like wearable a Daft Punk helmet, and now a Metroid Prime 3 Samus Aran Varia Suit.
Using her friends Zcorp 450 3D printers and a 3D model based on this one, Imgur user Talaaya first created a pepakura helmet to get the sizing right (you’ll want to be completely accurate when you print or it will be a very expensive mistake!), which she has included all the sizing files for the helmet and rest of the suit here. The helmet had to be printed in 4 pieces due to the size of the printer bed, and it required a lot of work to put them together. After gluing the pieces together, the peices became a little warped during the curing process (dipping the piece in or covering it with superglue) and to get everything lined back up, bondo and some grinding was required. Talaaya also points out that because 3D printers print in layers, the results have a grooved wood grain-like texture, which she filled with a thin layer of bondo and sanded down.
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