This one requires a large printer (larger than 280 × 280 × 235 mm). For smaller printers, see the remixes.

Check out the Daft Punk Thomas Helmet too: https://www.thingiverse.com/thing:5033571

Thank you to lukasantus for the photos of the finished product! His build video also covers some of the finishing and vacuum-forming process.

UPDATE 10/9/2026: The LED matrix frames and diffuser are now a single piece. Print in white.

Hardware

I've linked the McMaster page for each part. These links are more permanent and give full specs (and 3D models!), but you can also find M3 screw kits and insert kits on Amazon and elsewhere (some insert kits even include the soldering iron tip to install them) instead of buying each pack individually. Inserts and screws are highly recommended, but glue works if it's your only option.

• (14) M3 x 0.5 mm Brass Inserts or kit from Amazon
• (10) M3 x 0.5 mm Flat Head Screw, 5 mm long (18-8 stainless, hex drive)
• (4) M3 x 0.5 mm Flat Head Screw, 8 mm long (18-8 stainless, hex drive)
• (14) Finishing Washer (18-8 stainless)

Install the inserts with a soldering iron.

Ear EKG (Optional)

Included in the files as both .dxf (for laser cutting, Cricut, etc.) and .stl (for printing). Compatible with the ALEXPLUSLEDS Guy-Man RGB Ear Kit (EKG only).

Visor

You don't need to print visor.stl; it's included for completeness.

Print the buck, sand and Bondo it smooth, then use it to vacuum-form the visor. Expect to make several: there are plenty of chances to mess one up, and you'll want backups. Pre-tinted material works best, but you can also tint with iDye Poly, spray with VHT Nite-Shades, or have an automotive tint shop do it.

LED Matrices

LED Frame
Print in white filament so it diffuses the light. You can print just the side pieces, or print the one with the center support for the center matrix.

LED Inner Cover
These parts are modeled flat and get formed to the frame after printing or cutting. Two options:

• Print: Use the 0.5 mm STL. For a thicker cover, scale the Z axis only.
• Cut: Use the DXF to cut 0.5–1 mm plastic sheet on a laser cutter, Cricut, etc.

To form the cover:

1. Remove the printed part from the bed.
2. Set it back on the bed and heat until it's soft and pliable.
3. Bend it around the LED Frame and hold it until it cools.

LED Matrix Hardware

• (8) M3 x 0.5 mm Flat Head Screw, 18 mm long (18-8 stainless, hex drive)
• (10) M3 x 0.5 mm Flat Head Screw, 5 mm long (18-8 stainless, hex drive)

Older version: For the earlier design with separate diffusers, see this remix: https://www.thingiverse.com/thing:7420428