Pulse Blade
Project Type
Costume
Date
2026-Present
Skills
3D Printing, Blender, Illustrator, Laser Cutting, Vinyl Cutting, Soldering, Electronics
Ongoing project documenting the process of constructing a Pulse Blade Pilot costume from Titanfall 2.
Helmet
Similarly to the ODST project, I'm primarily using files from Titlewave Designs. He sells a set that includes 3D print files for the helmet and body armor. His models are detailed, high quality, and fairly accurate to the in-game assets. However, there are still a few modifications that need to be made prior to printing.
Using Blender, I boolean holes(marked with red) into the helmet, either for LEDs or for wires to pass through. In hindsight, I should have added more holes for ventilation, attachment points, inset electronics, and magnets.
I use Armorsmith Designer in order to scale the files to my size. While the program is amazing, it isn't accurate for every single body part, so care should be taken to ensure the part is properly scaled. Consideration should also be taken for auxillary components, such as hair, head mask, padding, and electronics. Case in point, the helmet is scaled to 93% uniformly of it's original size in Armorsmith, but is slightly too small in reality, to the point where a balaclava is the difference between a fit.
Unlike my ODST, which was printed on a Neptune 4 plus(320 x 320 x 385mm), This helmet is being printed on a Centauri Carbon(256^3 mm). This means that the helmet needs to be split up into more parts, 4 in this case. I'm still printing with PETG for its ease of use, durability, and higher melting point. The files come with the atachments separately, so naturally those are printed separately.