Why most cosplay armor STLs fail on FDM
A lot of armor files look fine in the slicer and still crack at the collar or warp off the bed at hour 11.
The usual issues:
Walls too thin for a wearable. If it is going on a body, you want 4+ walls, not 2.
One giant mesh. Helmets and chest plates should arrive pre-split, already oriented, with flats that actually sit on the bed.
Support nightmare. If the file needs a forest of supports inside a visor, it was modeled for resin, not FDM.
Wet filament on a 12-hour PETG plate. Dry it first. A brim is cheaper than a reprint.
I sell print-ready armor files built for FDM, and a separate 1-hour live session if the printer itself is the bottleneck. Different products on purpose. Files should not expire. Repair time should.
