Samus helmet foam pattern

PDF pattern 100% scale for 54cm head circumference. Print using adobe reader poster print across multiple paper sheets and tape together for a full scale pattern print! Uses 5 to 10mm eva foam (if using thicker eva foam, use a lower density than 65kg/m3). This is an optimized one-side-only print, flip the pattern pieces labeled 'M' to get the other side as well.
Dremel the foam edges to get the defined lines in your helmet. Use clear plastic for the visor, 2mm petg works well. You can use headlight foil tint to get the green color. Recommended to use cable wrap (cable tidy tube, or corrugated cable tube) to create the tubes below the visor.