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About Project

Most people only see the outside of an SLA print. This project lets us look inside-and what you find there is surprisingly beautiful. Using SLA Castable Resin with the QuickCast庐 build style, we created a transparent Stormtrooper helmet that reveals the intricate hollow-lattice structure normally hidden inside investment-casting patterns.

At first glance, the helmet looks like a clean, crystal-like sculpture. But look a little closer and you’ll notice a delicate geometric texture flowing beneath the surface. This isn’t decorative infill-it’s the engineered hexagonal lattice that makes QuickCast patterns so effective for investment casting. The lattice supports the thin outer shell, controls shrink stress, and ensures the resin burns out smoothly during metal casting. When printed in a clear resin and lit from the front, this functional structure becomes a striking design feature all on its own.

What makes this project special is how it highlights the dual nature of SLA castable materials:

• Technically, they’re optimized for low ash, predictable collapse, and dimensional accuracy in high-end casting workflows.
• Visually, they offer unique transparency that transforms engineering logic into an artistic aesthetic.

QuickCast is widely used in aerospace components, turbocharger wheels, medical devices, jewelry casting, and any metal part where precision really matters. Yet when you leave the pattern unburned-like we did here-you gain a rare chance to see the technology’s inner workings with your own eyes. The result is both educational and unexpectedly beautiful.

This Stormtrooper helmet has now become one of our favorite display pieces. It lets engineers, designers, and curious newcomers understand how castable SLA patterns are built, and why the hollow-lattice structure is so essential. It’s also a reminder that manufacturing technologies often contain their own hidden artistry.

Work With FacFox

At FacFox, we produce high-accuracy SLA QuickCast patterns for aerospace, automotive, jewelry, and prototype metal casting-along with display pieces like this one that showcase the technology’s inner structure. Whether you need dependable casting patterns or want to experiment with translucent SLA aesthetics, we’re here to help you bring ideas to life with speed, precision, and care.

Let’s build something remarkable together.

Solution

• Step 1: Model Preparation. The Stormtrooper helmet CAD file was prepared with uniform wall thickness suitable for the QuickCast庐 build style, and the geometry was checked to ensure it could be printed as a hollow shell with internal lattice.
• Step 2: Build Style & Orientation. The QuickCast build style was selected in the SLA preparation software, and the helmet was oriented to balance surface quality, support requirements, and drainage.
• Step 3: Support Generation. Necessary supports were generated automatically by the software and were adjusted manually where needed to protect key visual areas while maintaining print stability.
• Step 4: SLA Printing. The pattern was printed on an industrial SLA system using castable resin. During printing, a thin outer shell and the internal hex-lattice structure were formed layer by layer according to the QuickCast parameters.
• Step 5: Cleaning & Rinsing. After printing, the part was removed from the build platform and was rinsed in solvent to remove uncured resin from the outer surface and internal cavities as thoroughly as possible.
• Step 6: Support Removal. The supports were carefully removed by hand and with tools, and the attachment areas were smoothed to preserve the clean surface and transparency of the helmet.
• Step 7: Post-Curing. The helmet was post-cured under controlled UV conditions to fully stabilize the resin, after which it was inspected for dimensional accuracy, surface quality, and clarity.