Get an early start on Halloween by 3D printing a Jack Skellington mask

While Halloween is still months away, you may want to try to make this wearable Jack Skellington head considering how long it will take to print.

Maker Chris Bermant tells us that the finished version you see on this page took around 116 hours to print, with many more hours going into the finishing after that.

If you have a larger printer this time will be reduced, as Bermant needed to slice his into 29 separate pieces each taking four hours to complete plus extra time to remove them from the printer and start on the next one.

After using super glue to join all the pieces together, an epoxy resin was applied to both the inside and the outside of the head. After a lot of smoothing and sanding, a coat of grey primer was added to find any bad areas which were then sanded down.

Once the print was finally as smooth as possible, it was sprayed white for that skeletal look. Some stretchy black fabric was added to the eyes, nose and mouth, and you can see what a difference this makes as the version without the fabric is in the gallery below.

For comfort foam inserts line the top of the head, which also help to get a proper fit. All that epoxy resin brought the weight of the prop up to around three pounds (1.36 kilograms)

To make your own start with the files which are available for free from Thingiverse. We’ve been told that this model was made in 3DS Max with finishing work in Mudbox.

Bermant and his brother Andy Pitts spent around a week getting it perfect. Pitts created the general shape together with the cutouts for the eyes and nose and Bermant did the teeth, smoothing, piecing apart, and extra features such as the eyebrows.

Those thinking of replicating this build need to remember to play around with the scale until it fits their head. The base model should fit most people, but it’s always worth making double or triple sure before committing the filament.

Previous 3D Prints of the Day:


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