At EGX 2016 my friend Stewie debuted his Corvo mask, several people have asked for information, so I consulted the man himself (Pictured below)
The mask 3D files are from: www.thingiverse.com/thing:537582
One of the .stl files is an assembled version, this is only used as a reference when building and shouldn’t be printed.
The Skull pieces & Bone charm were split when printing, to give better flat patches for the base of the printer and acetone fused before shipping by the chap that printed them (CNCVAC @ 3d Hubs).
All pieces were printed in ABS with a layer height of 200, PLA is probably too brittle if using for Cosplay, although may suffice if using as a decoration.
3D Hubs allow you to upload .stl files individually or zipped & then get an initial quote from your nearest printers. Additional costs may then be negotiated for things like file altering and support removal.
The fabric is just a swatch of natural hessian attached with a sewing machine to a swatch of red velvet-esque material, I didn’t use the measurements provided on the image on thingiverse, mainly because I forgot it was there. I’d recommend using clear nail polish on the edge of the hessian to prevent fraying.
Paints used were water-based acrylic model paint, Vallejo and Citadel brands specifically. I painted and clear-coated before assembly, then touched-up worn areas after.
I’d recommend epoxy for the joints, rather than superglue, the latter didn’t quite cut it on some joints.
In addition to the printed parts I used cut offs from the spur of a citadel model kit to both strengthen the connection between the skull pieces and to connect the straps to the mask.
The straps to secure the mask were sourced online from a mask store.
The 3D Printing was around £80.00, where 3d Hubs were used, you may have access or know someone who may be able to do this for you, or you may wish to check out you favourite search engine and look for 3D Printing Services, as it is a growth business.
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