So i’m trying to print a full scale iron man helmet. I want to print it in a material that looks and feels like metal. Copperfill and Bronzefill by Colorfabb is the closet I have come. These materials are far too brittle and wouldn’t be ideal for a helmet. I want the helmet to be usable so wear and tear is a must! The material can’t be too expensive either. Thanks for anything you come up with 
You can try Proto-Pasta Stainless Steel. I can be fragile but I can but I am not sure of the purpose you are looking for.
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Thanks for the reply. What is the difference between Proto-Pasta and Copperfill/Bronzefill? I want to use the helmet as an actual helmet so wear and tear is a must. Do they both need to be polished? How fragile are each of them?
I am not sure of the copperfil you have but the brand I have looks quite cheap where I can tell you from my experience that you can polish the Proto-Pasta Stainless Steel, Proto-Pasta sells a polishing kit if you don’t want to go out and buy your own. I haven’t exactly tested how strong the SS is but I haven’t had a problem with it being very fragile but when I do print with it I use about 4 layer thick walls. I can say that my prints are quite heavy for their sizes due to the thickness. I k now for about $10 you can buy a sample from them and test it before you decide. I believe you can even buy their filament from Amazon.
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Is there a way for you to test the SS and let me know how strong it is? I am trying to print a helmet so there will be a lot of unsupported material after it’s done printing. Thanks in advance.
My personal opinion would be it would work without a problem with 3 or 4 layer walls you just have to deal with the weight.
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JH3D
7
What type of helmet is it, and what is its intended use? While I can’t wiegh in on the filament suggestions, if this has anything at all to do with safety and protection for yourself or others, I would strongly advise against using it for that purpose. There are reasons helmet manufacturers have large budgets for R&D and Legal…
Mirth
8
Honestly, here’s what I’d do;
1. Print in PLA slices and attach together.
2. Apply car filler and sand till you have a smooth finish.
3. Make a silicone mould of the piece.
4. Apply aluminium/copper powder to the inside for cold casting and pour in resin. Bill Doran on youtube has a good series on this.
TypeR
9
Are you REALLY gonna use a 3D printed helmet for real-life applications?
What kind of use do you have for it?
At this moment, I have an order for the inner shell for a full-size helmet, but it is ment as a prototype, not as a helmet you would actually wear.
I would never use a home made 3D printed helmet for (motor)cycling or any other activity where a serious fall could mean permanent injury when using an improper helmet.
Let me ask you a simple question: Do you have a 10$ head or 1.000.000$ head. If you answer is 10$, than it is ok to use a 10$ helmet.
However, if you are using a helmet for things like re-enactment, by all means, go ahead 
For strenght however, never use a material like bronzefill or protopasta. These additives are ment for looks, not necessarily for strength.
If you need strength, go for a PETG or XT, of NGEN-printed product. It has strength ánd flexibility.
And make sure you have the material some heft as well.
Mirth
10
I took it as being a cosplay helmet. No one would be silly enough to 3D print a safety helmet, surely?
JH3D
11
Using the internet teaches you one universal truth: Common Sense isn’t common at all.
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This is not an actual helmet!? This is a iron man helmet! Thanks for the material suggestions though. Do you recommend just one?
Thanks so much, I will look into this!
Is this a standard option or something I have to discuss with a hub?
This is an iron man helmet. A toy!
You’re right about that. This is an iron man helmet! Who would print an actual helmet? Haha
Iron man teaches common sense!
Mirth
18
That’s… witty and very very true!
This is looking too expensive 
Is that 3 to 4mm wide walls?
