Update: Adafruit has featured my design! See here for assembly instructions and adding LEDs and motion sensors:

https://learn.adafruit.com/spacex-helmet/

Opening SpaceX Helmet Replica. It is a work in progress, but as of this point you can print a functioning helmet! Well, 'functioning' meaning it opens, don't try to go to space with it. And don't use it for protection.

You will need a fairly large bed, the largest part of the assembly is 240mm x 209mm. Parts can be glued together or bolted together with inserts and screws.

####Inserts and screws (about $20 worth):

• M3 x 0.50 mm Brass Inserts: https://www.mcmaster.com/94459a130

• 18-8 Stainless Steel Hex Drive Flat Head Screw, M3 x 0.5 mm Thread, 5 mm Long: https://www.mcmaster.com/92125a125

• 18-8 Stainless Steel Hex Drive Flat Head Screw, M3 x 0.5 mm Thread, 8 mm Long: https://www.mcmaster.com/92125a128

• 18-8 Stainless Steel Hex Drive Flat Head Screw, M3 x 0.5 mm Thread, 12 mm Long: https://www.mcmaster.com/92125a132

Use a soldering iron to install the inserts.

Visor mold for vacuum forming is included; as you can see in the pictures I haven't molded one yet. If you do, please give feedback!

The dimples in the vacuum formed visor are meant to be drilled out. Attach the visor to the helmet with screws, inserts, and these washers:

https://www.mcmaster.com/98472A200/

If you are planning on doing some additional finishing (bondo, paint, etc) the screw holes on the back of the helmet are meant to be filled in. If you are printing it and using it without additional finishing, use the Outer Shell without the unsightly screw holes (will need to be glued together): https://www.thingiverse.com/thing:3473499

Update 6/8/2020: I uploaded the inner and outer shells in one piece for very large printers

Update 6/22/2020: Reinforced the back of the visor mold due to reports of it buckling during vacuum forming