We're trying to print the headset with a machine that has a printing volume of 20x20x20 cm (that's a little bit less than 8x8x8") and the medium size ultracortex helmet barely fits, but it does fit.
You need to set it up diagonally at 45 degree angle to fit and print it in PLA or the most "dimensionally stable and warp-proof" plastic you have. We're printing it with 0,3mm layers 15% infill and it's a 24 hr print per half at 60 mm/s (prusa i3 with 0.3mm nozzle). For the helmets you need to add support and I recommend you to add some brim if you can (we barely can fit 3mm (1/8" of brim). That will help stabilize the first layers as the print starts with a high aspect ratio in some places and the "studs" being printed can be toppled if they aren't well adhered.
Also, for this print use the slicing software that has the best support matterial handling. We use cura for this print, as it handles supports very well and they can be easily removed later. So far one half of this print has failed us twice, once because we set too few infill and infill threshold and it turned out too fragile and broke apart and the other because the extruder got jammed during printing, but we hope to get it right the next try. It's about 150g of plastic per half or so, let me check and I'll tell you tomorrow how much it actually is.
For the octabolts we used the same prusa i3 printer, printing with PLA at 0,2mm layer height at 20% infill, no support and no brim. For these pieces use the slicing software that has the best dimmensional accuracy. We use Slic3r for this, as it handles corners and overall dimensions much much nicer than Cura, but it's crap for support material. We've already printed several octabolts this way and they work straight out of the printer, no sanding/filing needed (we sand them a bit to improve the feel but it woudn't be neccesary).
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We're trying to print the headset with a machine that has a printing volume of 20x20x20 cm (that's a little bit less than 8x8x8") and the medium size ultracortex helmet barely fits, but it does fit.
You need to set it up diagonally at 45 degree angle to fit and print it in PLA or the most "dimensionally stable and warp-proof" plastic you have. We're printing it with 0,3mm layers 15% infill and it's a 24 hr print per half at 60 mm/s (prusa i3 with 0.3mm nozzle). For the helmets you need to add support and I recommend you to add some brim if you can (we barely can fit 3mm (1/8" of brim). That will help stabilize the first layers as the print starts with a high aspect ratio in some places and the "studs" being printed can be toppled if they aren't well adhered.
Also, for this print use the slicing software that has the best support matterial handling. We use cura for this print, as it handles supports very well and they can be easily removed later. So far one half of this print has failed us twice, once because we set too few infill and infill threshold and it turned out too fragile and broke apart and the other because the extruder got jammed during printing, but we hope to get it right the next try. It's about 150g of plastic per half or so, let me check and I'll tell you tomorrow how much it actually is.
For the octabolts we used the same prusa i3 printer, printing with PLA at 0,2mm layer height at 20% infill, no support and no brim. For these pieces use the slicing software that has the best dimmensional accuracy. We use Slic3r for this, as it handles corners and overall dimensions much much nicer than Cura, but it's crap for support material. We've already printed several octabolts this way and they work straight out of the printer, no sanding/filing needed (we sand them a bit to improve the feel but it woudn't be neccesary).
Good luck!