I'm making my costume out of many sets of files, based on how well they work/accurate they look.

These are the main files that most people have been printing. They are the Jesse M. files. They appear quite accurate, but I've discovered that there are many differences from the screen used suits. (only fanatics would really notice). I'm using these for half my suit, however most of the parts were modified to fit my needs.


These files are scans of recasts of the actual suit. They are decently accurate to the original trilogy version, but some parts aren't the best for working for a costume, and there are some parts that aren't quite movie accurate for some reason, its as if they've been resculpted in some areas. The details are very dull too. I originally wanted to use a lot of these, but I ended up using a combination of the Jesse files, and my own.





I hired some freelance 3d modelers make me some files for the torso and head to be much more of a replica. Made both a sequels and original trilogy version of the torso. The Don post scans were used as reference, giving the files a lineage asymmetrical look, while still making things nicer looking than the scans.

 
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These Jesse M files and the don post 3d scan files are using a smaller scale than the real screen used suit. This is because they are based from the Don post statue, which had shrinkage when they casted it from the screen used suit. Nobody in public really reveals the proper measurements of the screen used suit. But most people say to scale the files up to 104-106%. I printed mine at 105% for most parts. Know that the biceps can run too tight at 105% if you have too much muscle or slightly thicker arms.
 
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For the shorts, you'll need flexibility in order to walk.

If you dont want to mess with rubber, than you'll probably have to use the Jesse M shorts and print in TPU or FPLA. I eventually made a FPLA version because the molded rubber one was pretty fragile, but it seriously limited the flexibility and leg movement.

At the end, I ended up getting a large resin printer and printing the shorts in rubber like resin. I also did the same for the feet.
 
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I print my parts in PLA plus on a CR-10 S5 and recently an Ender 3 pro (smaller parts only)
 
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For the feet, I bought a pair of Kung Fu shoes from Amazon to wear underneath. The 3po feet will fit on top, without a sole.
 

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in order to be able to wear 3po shoes, I got rubber resin printed shoe covers!
 

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