Helldivers 2 Helmet: Assembling the Defense of Super Earth

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Attention, Helldivers! The forge is open and a new build is underway. Today on the workbench, we are assembling a fresh Helldivers 2 inspired helmet to join the front lines.

This design is a favorite in the workshop. It has a fantastic, aggressive silhouette with distinct armor plating, detailed ventilation systems, and a wide visor recess. Because of its complex angles and overhangs, printing it in multiple sections is the best way to maintain clean surface details and maximize print quality.

Now, it's time to bring those pieces together into a shell strong enough to survive a bug drop (or at least a busy convention floor).

Here is how the assembly process went

1. Cleaning the Prints: Before glueing, I used a hobby knife and deburring tool to clean up any support contact points and brim material. Getting clean edges is essential for tight seams.

2. Alignment Check: The Helldivers helmet has several key alignment points, especially around the jawline and the visor frame. If these are off by even a millimeter, the visor won't fit correctly later. I spent extra time dry-fitting these segments to ensure they aligned perfectly.

3. CA Glue & Activator: Using high-viscosity CA glue, I bonded the main jaw and faceplate sections first, curing them instantly with activator spray. This gives a fast, strong hold so I can verify the symmetry before moving to the dome.

4. Internal Welding: Once the shape was locked in, I used a soldering iron to weld the seams on the inside. This fuses the PLA plastic together, providing the structural integrity needed for a wearable cosplay helmet.

5. Seam Reinforcement: On the outside, I ran a small bead of CA glue along the seams to fill any micro-gaps, which will make the initial sanding pass much easier.

With assembly complete, the Helldivers helmet is now in its raw, unrefined state. You can see the gray plastic segments, the welded seam lines, and the industrial look of the unfinished shell. But the alignment is spot-on, the structure is solid, and it's already looking like a proper piece of combat gear.

Next up for this build is the sanding and priming phase, followed by base paints, and then the absolute best part: adding layers of grime, carbon scoring, and physical battle damage to make it look like it just survived Malevelon Creek.

Check out the raw assembly photos in the gallery, and remember: Freedom never sleeps, and neither do the printers!

Keep Exploring

Want to see more of the build process? Visit the workshop page for behind-the-scenes progress, or browse the finished prop catalog to see what is available now and what is open for pre-order.