WIP 3D print PLA TLJ Phasma Build!

[MikeWazowski[TK]]

Hello all! I’m so excited and terrified to share my progress on my build!

 

My goal is to 3D print the entire suit. I still have a few pieces left to both design and print. I’ve heard that my greeblies may be a bit too square and would love y’all’s input! Any feedback you have on any of the parts or build would be greatly appreciated!!

 

Thank you thank you thank you!!

 

[gmrhodes13[Staff]]

With 3D prints I like to sand everything first with 80grit sandpaper, this will get rid of most of the lines, I then apply 3 coasts of spray putty (primer filler in other parts of the world). Leave dry for a few days, wet sand, makes the paper last longer and less dust. Spot (blade) putty for anything remaining then wet sand those areas again. Coat with primer and you are ready for paint.

 

Prep work is the key, especially for a character with such a shiny appearance.

 

Looking forward to seeing your progress

[MikeWazowski[TK]]

Thank you!!

 

I have never done a wet sand but keep reading that it’s the best! I’m also stoked to get my sand paper to last a little longer!!

 

Thank you again and hopefully I’ll be able to post a meaningful update (and not just “I’m still sanding!”) in the near future!! 

[MikeWazowski[TK]]

Pretty stoked about this first layer of gloss black! She's giving reflective!

Edited February 25, 2024 by MikeWazowski
Posted an embedded link from Imgur, didn't work, went back and deleted to just say "test," now adding a resized copy of the original image

[gmrhodes13[Staff]]

30 minutes ago, MikeWazowski said:

Pretty stoked about this first layer of gloss black! She's giving reflective!

Nice work, may be a reflection but can see a few print lines still?

 

Be very careful applying paint and make sure the part is completely dry, thinners in paint can soften filler/primer and allow lines to be more noticeable. Rather say something now than see you apply a top coat  

[MikeWazowski[TK]]

Has anyone run into any issues where the airbrush works just fine until you put the Alclad in? ? I’m working with a Master Airbrush G22. Distilled water sprays fine, paint sprays fine, Alclad sprays fine for maybe 10-15 seconds, then just air. I’ve shaken the Alclad forever, I’ve tried higher PSI, and I’ve completely disassembled, cleaned, and reassembled the brush, and same issue.

 

If anyone has any tips, I would be incredibly appreciative!! Thank you!!

[gmrhodes13[Staff]]

1 hour ago, MikeWazowski said:

Has anyone run into any issues where the airbrush works just fine until you put the Alclad in? ? I’m working with a Master Airbrush G22. Distilled water sprays fine, paint sprays fine, Alclad sprays fine for maybe 10-15 seconds, then just air. I’ve shaken the Alclad forever, I’ve tried higher PSI, and I’ve completely disassembled, cleaned, and reassembled the brush, and same issue.

 

If anyone has any tips, I would be incredibly appreciative!! Thank you!!

What nozzle do you have, I have used alcad with a 0.5 nozzle (same for aluminuster) and had no issues. I did find it sprayed better with a lower air flow. You can adjust the flow on the rear of the brush on most models.

[themaninthesuitcase[Admin]]

1 hour ago, MikeWazowski said:

I’ve tried higher PSI,

Alcald quote a pretty low pressure, 15PSI from what I remember.  I've not had this issue on my very cheap 0.4 nozzle air brush.  When I got my best results it was with barely any paint actually coming out of the air brush, mostly just the air.

 

This is a handy guide for alclad I used before:

https://www.snmstuff.co.uk/alclad-ii-faq/

[MikeWazowski[TK]]

I didn’t even think about nozzle size! I think I’m rocking a 0.3 so I will try bumping up to troubleshoot! Thank you for mentioning the better results with less output. I last used the airbrush for a larger piece just coating it with paint so I’m definitely used to more and faster coverage.

 

thank you thank you thank you!!!

[TheRascalKing[TK]]

Please consider printing my greeblies in resin to sharpen up your kit!
 

PLA isn't considered a particularly robust material for cosplay, especially in the heat, so keep us posted how it holds up!

Edited June 15, 2024 by TheRascalKing

[Sly11[Admin]]

23 hours ago, TheRascalKing said:

Please consider printing my greeblies in resin to sharper up your kit!
 

PLA isn't considered a particularly robust material for cosplay, especially in the heat, so keep us posted how it holds up!

This is a wise consideration, not only for the sharpness of a resin print but the details are pretty darn accurate.

[MikeWazowski[TK]]

Ooooooh that’s such a good idea, thank you! I will absolutely do that as my resin printer is currently collecting dust lol

 

I plan on going back and printing … probably the majority of the suit again before submitting for approval. ? About 85% was done on a very old CR-10 and I’d like to clean them up on my K1 Max. I’m a little afraid of ABS but is that the best way to go? 

[TheRascalKing[TK]]

1 hour ago, MikeWazowski said:

Ooooooh that’s such a good idea, thank you! I will absolutely do that as my resin printer is currently collecting dust lol

 

I plan on going back and printing … probably the majority of the suit again before submitting for approval. ? About 85% was done on a very old CR-10 and I’d like to clean them up on my K1 Max. I’m a little afraid of ABS but is that the best way to go? 

 

Since the K1 Max is enclosed, ABS is generally best if you can print it consistently. If not, many of us at least use PETG over PLA.

[themaninthesuitcase[Admin]]

I only use PETG for my cosplay parts, though I keep looking at ABS now I have an enclosed printer.

[MikeWazowski[TK]]

Thank you all. I was intimidated to ask here and you all are so kind, thank you so much! 

[Morganzola]

Do you have a link to the files you used? I'm interested in printing a Phasma build as well.

[MikeWazowski[TK]]

Absolutely! https://www.do3d.com/product-page/captain-phasma-helmet-armor-suit-star-wars-3d-printable-model-project-32-1

 

I had to email them to get the biceps and I made my own feet and cod pieces, but this was so so so much fun and amazing files <3 

 

Let me know if you have any questions!

[Morganzola]

14 hours ago, MikeWazowski said:

Absolutely! https://www.do3d.com/product-page/captain-phasma-helmet-armor-suit-star-wars-3d-printable-model-project-32-1

 

I had to email them to get the biceps and I made my own feet and cod pieces, but this was so so so much fun and amazing files <3 

 

Let me know if you have any questions!

 

Thanks! I'm probably not going to start on it right away, I have some other cosplay projects on my list, but I'm hoping to start mine in the next year.

 

What modifications did you make on the feet and cod piece? It does seem like the file photos are a little off on the shape, but idk for sure.

 

Did you run into any trouble with the fingers? The do3d file appears to have the rounded knuckle bumps like the TFA version, but you did a TLJ build right?

[MikeWazowski[TK]]

On 5/21/2026 at 12:15 PM, Morganzola said:

 

Thanks! I'm probably not going to start on it right away, I have some other cosplay projects on my list, but I'm hoping to start mine in the next year.

 

What modifications did you make on the feet and cod piece? It does seem like the file photos are a little off on the shape, but idk for sure.

 

Did you run into any trouble with the fingers? The do3d file appears to have the rounded knuckle bumps like the TFA version, but you did a TLJ build right?

If I remember correctly, I don't think they were included at all. I just threw some together in tinkercad and melted them to the right forms! The only one I really struggle with was the biceps and so I emailed Do3d and they sent me files for the biceps, so I wouldn't be surprised if the creator has those files and maybe just forgot them in the posting.

 

For the fingers, they were the TLJ fingers in the file!

[Morganzola]

On 5/23/2026 at 7:04 AM, MikeWazowski said:

If I remember correctly, I don't think they were included at all. I just threw some together in tinkercad and melted them to the right forms! The only one I really struggle with was the biceps and so I emailed Do3d and they sent me files for the biceps, so I wouldn't be surprised if the creator has those files and maybe just forgot them in the posting.

 

For the fingers, they were the TLJ fingers in the file!

 

Oh nice! I saw some raw print photos on their listing that had the ridges, but they must've updated the model. 

 

What are you doing for the finish? I'm thinking I'll print in ABS for strength and temp resistance and acetone welding pieces together easily, then vapor smoothing. I've seen some mando folks layering 2k clear coat and graphite powder and that's where I'm leaning. I've also found some silver ABS so that combined with the multiple graphite/clear coat layers should help with any deep scratches not showing a drastically different color underneath.

[MikeWazowski[TK]]

22 hours ago, Morganzola said:

 

Oh nice! I saw some raw print photos on their listing that had the ridges, but they must've updated the model. 

 

What are you doing for the finish? I'm thinking I'll print in ABS for strength and temp resistance and acetone welding pieces together easily, then vapor smoothing. I've seen some mando folks layering 2k clear coat and graphite powder and that's where I'm leaning. I've also found some silver ABS so that combined with the multiple graphite/clear coat layers should help with any deep scratches not showing a drastically different color underneath.

That sounds like a great plan! I did my entire build in PLA, sandpaper, and 8000 gallons of elbow grease lol then I did rustoleum gray filler primer > I can’t remember if I did rustoleum, krylon, or a combo of glass black > alclad 🥰

[Morganzola]

44 minutes ago, MikeWazowski said:

That sounds like a great plan! I did my entire build in PLA, sandpaper, and 8000 gallons of elbow grease lol then I did rustoleum gray filler primer > I can’t remember if I did rustoleum, krylon, or a combo of glass black > alclad 🥰

 

Yeah I've heard great stuff about alclad, and I might go that route if a powder method doesn't turn out. From pics/vids I've seen I think graphite may turn out too dark for my liking, so I'm also going to do some tests with a chrome nail powder and atomized nickel silver to see if any of them will do the job.

 

I'm currently working on a anduril prop for my friend's birthday that I'm doing the sanding and filler primer method with and I do not envy you doing that on a full PLA suit lol good on you for putting in the work

[MikeWazowski[TK]]

29 minutes ago, Morganzola said:

 

Yeah I've heard great stuff about alclad, and I might go that route if a powder method doesn't turn out. From pics/vids I've seen I think graphite may turn out too dark for my liking, so I'm also going to do some tests with a chrome nail powder and atomized nickel silver to see if any of them will do the job.

 

I'm currently working on a anduril prop for my friend's birthday that I'm doing the sanding and filler primer method with and I do not envy you doing that on a full PLA suit lol good on you for putting in the work

yea it was rough and I am so thankful to have had an amazingly patient handler/husband while he helped me wiggle into it. Also if you’re interested, there is a Captain Phasma Costumers Facebook group which is where I got ALLLLLL my info. Those folks are so freakin next level AND friendly!! 

[Morganzola]

1 minute ago, MikeWazowski said:

yea it was rough and I am so thankful to have had an amazingly patient handler/husband while he helped me wiggle into it. Also if you’re interested, there is a Captain Phasma Costumers Facebook group which is where I got ALLLLLL my info. Those folks are so freakin next level AND friendly!! 

 

literally sent a join request last night lol just waiting on approval. I found them yesterday after someone on here mentioned a phasma FB group