Fan Punk Thomas Kit

Fan Punk Thomas Bangaltar Helmet — 3D Print File Pack

Printability / fitment status:

This project is printable and has been physically printed and tested through earlier versions. The current release is based on those test prints, with the problem areas corrected and the updated parts test-fit for tolerance and assembly.

I do not currently have a fresh full print of this exact latest file set photographed, but the design has gone through real-world print testing, fit checks, and revision. The shell, internal frame, ear assemblies, diffusers, magnet pockets, and mounting areas have been checked so the file pack should be ready to print, test-fit, and build.

As with any large cosplay helmet print, your printer calibration, filament, slicer settings, and support cleanup can affect final fit. I recommend dry-fitting all parts before gluing magnets, electronics, or diffusers. i designed this to print on a sunlu s9+ printer which has a build plate of 350x350x400 and this maxes out the footprint.

I have been working on this project off and on for a few years, and it is finally at a point where I am comfortable sharing it. There may still be minor fixes and personal changes over time, but the main helmet design is ready for builders.

I call this project Fan Punk because it is a fan-made, Daft Punk-inspired helmet focused specifically on wearability. The helmet is probably larger than a screen-accurate replica, but that extra space is intentional. It is designed to make room for cooling fans, LEDs, batteries, an Arduino or ESP32, wiring, switches, and optional 8x8 LED matrix sections.

This file pack includes the helmet shell, alternate chin draft shield version, internal frame parts, ear assemblies, side diffuser panels, and a draft assembly manual with a BOM, print file list, assembly order, wiring notes, and safety notes. The manual already covers the main shell choice, internal frame, ear caps, side panels, magnets, fans, buck converter, ESP32, NeoPixel parts, and MAX7219 matrix driver parts.

This is a passion project, and I am excited to share it with other makers, cosplayers, and robot helmet nerds.

Included
Main Thomas-style helmet shell
Alternate shell with chin draft shield
Internal frame parts
Ear cup and ear cap assemblies
Side housing and diffuser parts
Draft assembly manual
BOM and electronics notes
Magnet, fan, buck converter, ESP32, NeoPixel, and MAX7219 matrix notes
Update Policy

This listing will be updated as the project improves. Future updates may include better photos, wiring diagrams, fitment notes, revised parts, and updated manuals.

All future updates will be added to this same Cults3D listing. Previous buyers should be able to return to their purchase/download page and download the newest version at no extra cost.

Notes

This is a maker/cosplay project, not a certified safety product. Use proper battery protection, set the buck converter to 5V before connecting electronics, and test all wiring outside the helmet before wearing it.

Personal use only. Do not redistribute, resell, upload, remix for resale, or sell physical prints without a separate commercial license.

i designed this to be printed on the chin and i added supports underneath the ears and anything that was 45% or more for the most part, i removed som of the unnecessary areas in between the major support areas to reduce print time.