NOT rated for motor vehicle use, general safety equipment or Type 26/42/52 directed energy plasma cannons.
All designed in Autodesk Fusion 360
Note ChinFront_r1_0.stl has been updated to address artifact present in Makerware. Not apparent why, but single slice layer was appearing as just support near top of print. Piece flipped in netfabb and resaved, artifact goes away! All STL sliced with Makerware to x3g at medium profile 0.2mm layers, default settings, 2 shells, 10% infill, with raft and support. Latest Makerware suggests scaling some pieces to fit. DO NOT. All pieces will fit a Replicator 2 print area with simple rotation about the vertical axis and centering. The "down" face should be preserved for best results. Total build time for main body is ~60 hours on my Makerbot Replicator 2 in PLA. Including pins ( no visor or magnets ) is 680 grams, so you can budget one Kilo gram per helmet with raft, support and reprints. Don't forget some natural for your visor / inserts. Its 16 main pieces as per attached files, and 4 inserts / visor. Using the other "things" for combined pieces it comes down to 12 main pieces. You can get it down to 7 main + insert full plates by printing multiple pieces on one replicator 2 bed. All uploaded files have been preprocessed in netfabb basic for integrity and orientation. Generally Magnets used are 3/8 x 1/10 99K32.03 - 19 off http://www.leevalley.com/en/wood/page.aspx?p=32065&cat=1,42363,42348 Placed in 3/8 steel cups 99K32.52 - 15 off http://www.leevalley.com/en/wood/page.aspx?p=32066&cat=1,42363,42348&ap=1 Jowl insert retaining magnets are 1/4" x 1/10" 99K31.01 from same page again. - 4 off http://www.leevalley.com/en/wood/page.aspx?p=32065&cat=1,42363,42348 Tension pins throughout model are 1/8" x 3/4" as per 240-025 - 57 off ( just buy a box of 100 ) http://www.spaenaur.com/pdf/sectionE/E107.pdf Print, glue, pin for alignment during glueing. Magnet for snap attach of peak, chin and visor if desired. Add foam to fit for proper alignment. Use 5mm LED's in all inserts. - 6 off ( presently ) No grunts were spared in the making of this product. Enjoy.