I can't thank you enough for your work!
I'm determined to print this, so I will review the files and I can make you several suggestions or upload new files for your revision.
I already took a look at the faceplate and indeed there were several problems with it, but all those problems can be automatically repaired (with netfabb for example) so it isn't a problem at all.
The main problem to print this is the size of the model, it's too big for a "home printer". Even in a professional printer the helmet may need to be printed in several parts. Also the number of polygons is very high, my computer froze trying to slice the entire faceplate, but that was before I did the automatic repair with netfabb so maybe it was that...
Also, due to the size of the parts, they take many hours to print, this last Saturday I tried to print 1/4 of the faceplate (the right cheek, from the chin to the eye) and left my printer unattended... I came home to a clogged extruder and a piece only half printed
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I placed the part horizontally, so the ratio between support structure and actual print was pretty bad... next time I will try to print the faceplate in vertical, even if I have to divide it vertically in several places, this will help if one or two parts have a problem, so I won't have to reprint a big part.
And about the size of your helmet, as you said, it is very big! :lol
I wasn't sure if you did the part using metric or imperial measurements, now it's clear you used inches. Now that I can measure the helmet I will see what scale I need, but I was using a x20 scale to get the dimension I wanted for the faceplate. If you used inches that would mean a x25.4 instead a x20!! :lol
As I said, this is an excellent work, I will try to print it and report any problem so you can make it even better
EDIT: Also, for the moment I only can print in PLA, but I'm in the middle of upgrading my Ultimaker to print ABS, and I already have a spool of red ABS... I think I will print the helmet with that :lol
EDIT2: I'm very new to prop building, I'm just finishing my first pepakura helmet, but if I do a casting, you can count on getting a copy from me, but I can't promise the quality you see in other peoples builds :lol
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