Will you be making idealised armour from the Clone Wars series, or the "realistic" armour from the movies?
They are quite different.
I don't know too much about the Clone Wars-style, but the "realistic" movie-style is definitely not wearable if completely screen-accurate. First of all, the vacuuformed kits that have existed have been made in different sizes, and then the parts have had to be trimmed and joined to fit the wearer. The shin armour often has the scallop in the back as a separate piece, without which it wouldn't be possible to fit the foot through the bottom.
Accurate movie-style helmets are often in multiple pieces held together with magnets because the neck ring on the underside of the helmet is otherwise too narrow/short. Licensed replicas of movie clone helmets don't have neck rings.
I have neck rings on both my Phase 1 and Phase 2 movie-style helmets, which was possible with a couple of mods.
My Phase 1 helmet is slightly longer than screen-accurate overall, which allowed a long-enough neck-ring without it looking too weird. Before I found that I could build it that way, I had planned to build the neck ring as separate left and a right part at the expense of a seam in the front.
On my Phase 2 helmet the snout comes off leaving an opening from the back of the neck to the "teeth". By having the seam at the snout there is no added seam that is not in the original shape. The only concession to accuracy is that the neck ring is an U-shape instead of a circle: the difference is literally a few mm.
My helmets started out as casts that I modded by hand, but I would encourage you to check and tweak your 3D model if you can, before printing: that would be much easier.
Edit: There was an error earlier that switched the meaning of most of the post. I'm sorry.