Bounty hunters are popular in the Star Wars universe, and though Boba Fett is cool, so is Shae Vizla. The female Mandalorian from Star Wars: The Old Republic is awesome and has a wicked cool armor design. Taras built the helmet from the costume and started by making a CAD model. Once he was happy with it, he prepped them for 3D printing. He applied Bondo to any gaps:
After sanding the Bondo down, I applied a coat of Bondo glazing putty and left it to dry for half an hour in front of a heater. (Normally, this putty takes several hours to dry depending on thickness, however curing is expedited significantly with the use of heat.)
Next I sanded the putty smooth, and applied more putty to fill in the trouble spots.
I repeated this process over the course of 3 days (tackling the ears and antenna stalk the same way), at the end of which I had a smooth helmet, ready for priming!
Read more about the process at Mynock’s Den.