28-year-old engineer Luke Daley started a project to create his own Kylo Ren costume back in April after the Star Wars Celebration Anaheim showed off the next Star Wars villain's complete costume. He spent about 100 hours designing it in Solidworks before 3D printing various parts out on his LulzBot Taz 5, as well as several other parts on a Form 1+. He also had several larger parts 3D printed through Shapeways. Daley spent over 100 hours 3D printing parts and prototypes alone, and probably double that sanding, smoothing and casting the final product. You can read more about this project, and see tons of process pictures over on 3DPrint.com: http://3dprint.com/100172/3d-printed-kylo-ren-helmet/