3d printing vs foam?

[WarmasterDante]

hey guys as you may tell i'm new here and have a few questions on should i 3d print or make my armour from foam? i already own a 3d printer so that part is fine.

my plan is to make a halo reach inspired MJOLNIR armour as it is my favourite armour. I also wanted to see if 3d printing it would be better than making out of foam i haven't got files yet for either. my only concern with printing is getting the parts on ie the torso armour. and is doing a mixture a good or bad thing like some parts are printed for their strength and parts out of foam for comfort. im still looking into how to make foam armour but ready for the challenge it may bring. with it being my first piece i do have a lot of worries but from my little time spent here they maybe already answered. if 3d printing is a better choice and useing armour smith to resize it to fit me any suggestions on where to get some files for the MJOLNIR

thank you for taking the time to read this

 

[Parzival]

Moesizzlac has created many free models on Thingiverse if you choose to go the 3d printed route located here : https://www.thingiverse.com/moesizzlac/designs

I myself am not experienced enough with foam to work with it, so I have done 3d printed suits. Both have their ups and downs, as you had mentioned already comfortability with foam is way better than 3d prints. Same goes for the maneuverability and weight benefits foam carries over 3d printed armor.

There is a tutorial index that may help with specific portions of a suit located here : Tutorial Index

 

[KaeSpoon]

Welcome WarmasterDante!

This question is difficult to answer as both mediums have positives and negatives.
I can briefly summarize the two, but I suggest combing some threads about these two mediums.
Overview of prepping a 3D print: A Painting Guide: From Raw 3D Print to Con Ready, with Lojak
Overview of Foamsmithing: Foam Guide

Please understand that this is coming from someone who usually does Foamsmithing, so I am only speaking on behalf of information I have gathered from users who have 3D-printed suits. Also; what I am describing for 3D printed suits are rigid PLA suits, not TPU as I do not have as much experience and it is still an uncommon method at this time.

Pros of 3D printing:
-Once you understand the learning curve of your 3d printer and know how to avoid failures, printing parts isn't incredibly difficult.
-From my experience; If you are a more technical person over a creative person, this may be the route for you as foam has a learning curve.
-If prepped and finished correctly; you can have an incredible, real-looking suit.
-Most paints work well with rigid 3D prints, especially rattle-cans.

Cons of 3D printing:
-Lots of prep work or an expensive printer is required to make your prints look clean. This includes sanding, Bondo, and fiberglassing your prints if you're using PLA. Prepping a lower-quality print takes a lot of extra time to get a nice finish.
-3D prints are prone to breakage and cracking when pressure is put directly on the part, I often see this kind of damage during transport. Most 3D prints cannot flex and will crack under pressure unless you're using a special type of plastic, which has its difficulties.
-You cannot adjust or alter a finished print easily like you can with foam.
-3D prints using PLA or another type of dense plastic can be heavy, especially if extra walls or infill are used.
-Often you have less mobility if you're printing with dense plastic

Pros of Foamsmithing:
-Flexible, resilient parts that can be packed without the worry of integral cracking when "squished" or "crushed" down.
-Increased mobility, foam flexes while PLA does not. (There are now flexible 3D-printing plastics you can use to your advantage)
-Usually more comfortable than PLA 3D prints, which means a longer wear time.
-You are able to alter the pattern and make adjustments on the fly whenever you'd like to make the part fit you better.

Cons of Foamsmithing:
-Foamsmithing can be difficult and has a learning curve, it can be a challenge to get your parts to look clean, professional, and looking like real armor.
-Prone to creasing, foam tearing from stress on seams due to ill-fitting or "stretching", folds, and punctures due to the softer material.
-Time-consuming and tedious in a way that differs from 3d printing.
-Rattle-can paint coatings can crack when the foam flexes, so acrylic or latex paint is preferable.

These points are just a few examples of how these two mediums differ from each other. Think about what you want your armor to look like and what you want to do in your armor. Good luck!

 

[he4thbar]

Regardless of your choice armorsmith is an invaluable tool for either crafting medium.
I don't think I could give a better explanation then KaeSpoon
But as a foam stan, im gonna show you something I can do in foam that i'd probably be terrified to do in 3d print

That being said I love my 3d printed helmets/props and small pieces!