Foxhead Workshop · How-To Series

How to finish 3D printed armor

The full method for taking a raw 3D print to a smooth, bare-metal finish: the process we use on our own armor, straight from the workshop bench. Slicer settings, prep, the guide coat smoothing method, painting, and two paths to chrome that leave the part reading as metal. From there, weather it or add color and chip it back.

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

The steps to a professional finish: raw print to bare metal, then weather or color it.

Approach
The exact steps we use on our own armor, ordered for efficiency
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
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
Raw 3D printed armor parts prepared for primer
02

Raw Print to Primer Ready

Strip supports without scarring, join multi-part prints, fill the seams, and scuff for adhesion. The part comes out primer-ready.

Prep
04

Seal, Color & Gloss

Primer-sealer, base color, and a gloss layer straight from the gun.

Paint
06

Color & Top Coat

Optional: mask the chrome and lay color over the metal (Montana Gold), the base for a chipped, painted-metal look. Guide coming soon.

Color
07

Weathering

Battle damage, scoring, and chipping that age the bare metal (or the color coat) into a lived-in kit. Guide coming soon.

Weather
08

Maintenance & Care

Sealing, handling, and field repairs so the finish survives conventions.

Protect

Optional step Mirror Polish — Between paint and chrome, wet-sand and compound the clear to a true mirror. Skippable, but the deepest chrome starts from a mirror.

Reference & related

More from the workshop