While non-LEGO elements have always been taboo in the fandom, the BIONICLE community has had a long history of making custom masks. Mask makers have been doing everything from simple paint jobs to casting masks in metal. I have even tried my hand at making the Avohkraan, and although I succeeded, the materials have proven too brittle to make it worthwhile.
With the boom in 3D printing technology, many MOCers are turning to 3D printers, and even ordering custom parts from websites like Shapeways. Unfortunately, it’s still not quite to the point of affordability and ease of use where you can just grab a $500 printer, tack on a spool of filament and print a perfect copy every time. If you’re willing to put in some work and do some research however, buying your own printer is likely to pay for itself in as little as 20 successful mask prints.
One machine that caught my eye recently is this tiny little resin printer that runs a mere $99 USD as a kit you have to assemble, but that should be trivial for anyone who’s put together a LEGO set in that price range. Resin printers use an LCD screen to cure liquid resin in place as a lifting arm raises and lowers, compared to the more commonly seen FTL printers that move a heating element back and forth, extruding plastic as it goes. They come with their own unique problems to overcome, like cleaning and curing the models after printing and safely handling the liquid resin, but the resin printers typically boast a much higher resolution that results in a more detailed final product.
Although tiny, this printer is very compact and is practically the perfect size to print custom masks! If that’s all you plan to do, then this may be the perfect printer to consider. A YouTube user going by Uncle Jessy put together this video review going over the basics of the printer and does a good job of warning you of why it may or may not work out for you. He also has some suggestions for other (albeit bulkier) printers in a comparable price range that may prove to be better suited to your uses in the long run.
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