Darth Vader Chest Box

I have only printed this on my Anycubic Photon Mono 4K Resin printer (because that's all I had) when I was brand new to Onshape and 3d Printing.  Due to size limitations, I split the main model in 2 parts.  The final print was done with each piece individually, on about a 45degree angle with custom supports.  I just used a small (less is more) amount of super glue to attach the pieces afterwards.  I should have also used some plastic wood on the crack and sanded it down before painting, but I was impatient.  You may want to just try printing the whole thing at once, if you have a larger printer and knowledge of proper supporting (or you actually trust auto-support).  Over the LED holes, I glued-in clear ‘windows’ that I also 3d printed with clear resin.  Frankly, this could probably be cut out of any clear plastic and would have saved some time but I wanted them the perfect amount of ‘frostiness’ so the LED light balance was right.  I diffused them just a bit on the inside with sandpaper.    

After printing:   I made the straps from 1" nylon webbing--just folded over the end and sewed it to make a ‘fat end’ before inserting it through the oval shape holes inside the back, and out to the strap slots, secured with a bit of glue.  I used a plastic buckle once I had the size right. The photos probably explain this all better than I can.  I also hot-glued in a piece of foam to cover the electronics pocket, while still allowing access to change the battery.  The whole thing was hand-painted by my buddy, who loves painting minis (and had a wide selection of paints) but mainly because I didn't want to spend $40 on $1 worth of paint for one project.  

All of the electronics came in a kit, from eBay (about $35) that just runs off a 9V battery. I cut a small hole in the foam for the switch to stick out and hot-glued it from the inside. Actually, I designed a switch ‘stand’ but frankly I don't remember if I ended up using it or not.  I included the .stl just in case anyone wants to try it.  I also bought a kit of stickers from eBay (maybe $5?), that had the writing for each of the red lights and also had switch stickers and the red light sticker (the LED lights through it just fine).  I ended up using these, to get the color just right (again, the lack of paint selection).  

If you are wanting to point out the obvious, yes, I bought the helmet and light saber.  The helmet (Dark Series) is worth every penny and already comes with amazing sound effects.  

Well, I guess if you have questions, hit me up.  Hoping to get as many downloads as possible before May4th.  If you don't know why, this probably isn't for you.  :)

If you want to see any more pictures of the other costume components, find @BrettProjectGuy on Instagram.