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Props & Cosplay · 2025
Breaker Helm
A wearable 1:1 helmet with a hinged visor, printed in impact-resistant filament and finished to take stage lighting without blowing out.
The brief
A helmet that reads as heavy plate from ten metres and is comfortable enough to wear for a full convention day. Those two goals fight each other, and the resolution was to move all the visual mass to the brow and cheek lines while keeping the shell thin.
Build notes
Printed in ASA for heat tolerance, split into five sections with hidden dovetail joins. The visor runs on a friction hinge that holds any position without a detent.
Finishing
Automotive base coats over filler primer, sanded to 800 between passes, with a satin clear rather than gloss so stage lights read the form instead of the reflection.