If you are wanting to use it for cosplay… I would suggest using ABS instead of pla…
with a 3mm thickness… I have printed a warhammer 40k terminator helmet in ABS and it is solid as a rock…

Currently I am printing a storm trooper helmet from SW VII… again in ABS…

sliced into printible chunks and then solvent welded… Depending on the size it only is a roll of ABS… ($16-$25 depending)

Chris

Ok, thanks so much!