Foxhead Workshop · How-To Series

How to finish 3D printed armor

The full method for taking a raw 3D print to mirror-chrome beskar — the process we use on our own armor, straight from the workshop bench. Slicer settings, prep, the guide coat smoothing method, the paint stack, mirror polish, and two paths to chrome.

Each stage has numbered steps, photos and footage from the actual builds, and a checkpoint that tells you when to move on.

Start at Stage 01 Get the work holders
Finished beskar gauntlet with Whistling Birds dart tips lit — the result this series builds toward

Before you start

What you need before you start

This series documents the method we use on our own armor — not theory, the actual bench workflow, filmed while it happens. It works the same whether you printed our files or anyone else’s.

To begin, you need:

  • A printed part — FDM or resin, the method is the same
  • Gray filler primer and a contrasting sandable color for the guide coat
  • 400-grit wet/dry sandpaper, a sanding block, and spot putty
  • A respirator and ventilation for the solvent stages

Every stage ends with a checkpoint so you know when to move on. And test the full process on plastic spoons before you commit a hero piece.

Start at Stage 01

The finishing pipeline

Seven stages from raw print to mirror chrome.

Stages
Seven — from slicer settings to mirror chrome
Skill level
Beginner-friendly — every stage shows the method and ends in a checkpoint
Materials
FDM or resin — PLA, PETG, ABS all use the same process
Status
Stages 01–03 live now · 04–07 in production from new shop footage
Print orientation and support setup for a cosplay armor part in the slicer
01

Slicer Settings for Cosplay

Orientation, supports, and the slicer settings that save hours of post-processing. A clean print is the cheapest smoothing you will ever do.

Print
04

Paint Stack: Sealer, Base & Gloss

Primer-sealer, base color, and a gloss layer straight from the gun. In production from new shop footage — coming soon.

Paint
05

Mirror Polish

Wet-sand the gloss and compound it to a true mirror before any chrome goes on. In production — coming soon.

Polish
06

Chrome: Graphite & Alumaluster

Two paths to beskar: buffed graphite powder or sprayed Alumaluster. In production — coming soon.

Chrome
07

Durability & Care

Sealing, handling, and field repairs so the finish survives conventions. In production — coming soon.

Protect

Reference & related

More from the workshop

Wet Sanding Station Setup

The bench setup behind the sanding stages. In production — coming soon.

Workshop