3D-Printed Cosplay Armor and Props in SLS Nylon

Why SLS suits cosplay

• No support marks. The part is held by unfused powder while it is printed, so undersides, visors and filigree come out without support scars to sand off.
• Fine layers on curves. Layers are thin (0.12 mm or less on the FORMIGA) and the surface is blasted and polished; it is matte and slightly grainy, which is a good base for primer.
• Thin, tough shells. PA 12 bends before it breaks (EOS gives PA 2200 an elongation at break of 18 % within the layer plane), so a 2 mm armor plate survives knocks that would crack a brittle print.
• Light. EOS gives a density of 0.93 g/cm³; a hollow helmet stays wearable.
• Moving parts in one print. Hinges, articulated fingers and scale mail can come out assembled.

What to print

Size and segmenting

The chamber of the EOS FORMIGA P 110 Velocis is 200 × 250 × 330 mm nominal. A face plate or a gauntlet fits in one piece; a full helmet, a chest plate or a long prop usually has to be split. Good split lines follow the design: panel lines, edges of trims, the line between visor and dome. Add keys, pins or overlapping flanges so the segments align, and glue or screw them together. The calculator shows for each segment whether it fits the chamber and in which orientation.

Hollow parts and weight

Price and weight follow the volume of material, so solid props are heavy and expensive. Shell the model in CAD to an even wall of 1.5 to 3 mm. Closed hollows are a problem in SLS: the unfused powder stays inside. Every cavity needs escape holes, at least two of at least 5 mm, placed where they will be hidden, for example inside a grip or behind a trim. The calculator flags enclosed cavities. See hollow parts and escape holes.

Joints, straps and moving parts

• Print-in-place hinges need gaps of about 0.5 mm and a path for the powder to leave; see print-in-place hinges.
• Scale mail and fabric-like panels are printed as interlocking tiles; see 3D-printed chainmail and fabrics.
• Clips and quick releases for armor plates work as snap fits in PA 12; see snap-fit joints.
• Strap slots and rivet holes are best printed in; holes for screws that are removed often get threaded inserts; see threads and inserts.

Color and painting

Every part is glass-bead blasted and polished; this is included in the price. You can order parts dyed: the dye colors the surface layer of the nylon instead of coating it, so it does not chip like paint. Black and orange are in stock; the other 59 colors add about one month (20 working days) at the same price. See dyeing SLS parts.

For metallic effects, weathering or glossy finishes, makers prime and paint the parts themselves. Test the primer and paint on a sample piece first. We do not paint parts and we do not offer chemical or vapor smoothing.

Details, text and emblems

Embossed and engraved symbols, runes and emblems print well when they are deep enough; see text and logos on SLS parts. Very thin spikes, horns and blade edges are fragile in any plastic: give them a thicker root or a rounded tip.

Limits

• Not protective equipment. Costume armor is decoration; we make no claims about protection against impacts.
• Heat: EOS gives a heat deflection temperature of 64 °C at 1.80 MPa for PA 2200; do not leave thin parts in a hot car under load.
• Licensed designs: print only models you have the right to use.

Ordering

Upload STEP or STL files of all segments together. Prices are shown to signed-in business accounts (free), so prop makers and studios register with their company details. Several props in one order also reach a higher volume discount on printing. Step by step: how to order SLS 3D printing online.

Frequently asked questions

Is SLS good for cosplay armor?

Yes, for many pieces. SLS prints without supports, so curved shells and fine details come out without support marks, and PA 12 is tough enough for thin armor plates. The surface is matte and slightly grainy rather than glossy.

How big can a printed helmet or armor piece be?

The chamber of the EOS FORMIGA P 110 Velocis is 200 × 250 × 330 mm nominal. Larger pieces are split into segments with keys or pins and glued or screwed together; the calculator shows whether each piece fits.

Can SLS parts be painted?

Yes. Makers usually prime and paint the blasted surface; test your primer and paint on a sample first. We do not paint parts, but we can dye them in 61 colors, which colors the surface layer instead of coating it.

How heavy are SLS nylon props?

EOS gives PA 2200 a density of 0.93 g/cm³, and SLS shells can be thin and hollow. Hollow parts need escape holes so the unfused powder can be removed.

Can moving joints be printed in one piece?

Yes. Hinged fingers, scale mail and chain-like elements can be printed assembled when the gaps are large enough, about 0.5 mm, and the powder can escape from between the parts.