Start by gluing the many prongs of the top dome of the helmet together along their edges. If you want to do these projects with kids, or just don't want to work with a sharp blade, check out Make-do Safe Saw: and other similar tools.12" x 8" strip of tinted film for the visor (if desired- be careful wearing as visibility is limited). GLOVES! Laser cut edges are sharp! Use gloves especially if working with laser-cut carboard.Two 18" x 24" cardboard sheets (if using the files linked above) OR cut the pieces from a cereal box or case of beer for a super silly stormtrooper.Print size is 18" x 24" (use acrobat to print it to multiple sheets if you are using a smaller printer) Sand the edges a bit for less risk of injury. Use gloves to avoid paper-cuts from laser cut cardboard (and hot glue). SAFETY NOTE: Always wear safety glasses when working with cutting tools. I have created downloadable template files to laser cut - or print, trace and cut your own cardboard or other ~1/4'' thick material. Here's a fun project for Halloween or just to create your own crazy Star Wars inspired creation.
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