When Replica Prop Forum (RPF) user Machinimax knew he wanted to be a Sith Lord, it had to be Darth Revan. He commissioned the lightsaber hilt but crafted the helmet on his own. He used a file from Thingverse and 3D printed the helmet over 19 hours and in two pieces. After printing, he sanded the segments and joined them together to prep for painting:
They were joined together with some super glue and I closed up any seams with some filler putty. You can see some of the sanding work here as well. To help with the sanding process I’ve been using a filler primer to help me pinpoint the target areas I need to focus on as well as fill in the small spots I can’t necessarily sand away. It looks good in this picture but in reality there was still plenty more to do. After sanding down the filler putty, it was ready for yet another coat of primer.
You can view a couple of work in progress pictures below.