3D Printing for Cosplay“From Foam to Filament”

Dave Lysen

Who and What?• A mild mannered Air Traffic Controller by day – cosplayer by night• Been building/creating cosplays since 2016• Work with Worbla, EVA Foam, 3D Prints and whatever else I can get

my hands on

Cosplay – a combination of the words costume and play, which is a performance art where a participant (cosplayer) wears a costume and accessories to represent a specific character

Adam Savage has a great TED Talk called “My Love Letter to Cosplay” – highly recommend it

Common Materials

• EVA Foam• Worbla• Sintra• PLA/PETG/ABS• Fillers• Primers• Paints• All the Sandpaper…

The Process• Pick your cosplay• Get reference material• Find/Make patterns (or files if 3D Printing)• Choose your material• Become MacGyver and figure out how to make amazing things out of

regular household items• Frustration• Tears• Youtube• Excitement• Repeat

Pattern Making - Hell hath no fury…• For armor or more fitted cosplays you will need the following

materials if no pattern exists• Plastic wrap• Duct tape• Markers• If doing a helmet – someone you trust with scissors by your face

Foam Vs 3D Printed Helm

Changing the GameThe K-2 Build

The K-2 Build

• 2018 – It’s announced Star Wars Celebration 2019 will be held in Chicago

• Why K-2? I had never found another cosplayer in a K-2 suit.

• Things I had to do to make K-2 a reality• Learn to walk on stilts• Figure out how to make articulating hands• Create the armor patterns for the entire droid

e-NABLE to the Rescue

IG: @unboundgeekdom e-mail: unboundgeekdom@gmail.comClick the above picture for Jeremy’s full story on the build