If the first layer is ugly, the prop is already dead
Most failed cosplay prints aren’t a “bad STL.” They’re a first layer that never stuck and a nozzle that was 5° too cold.
On Bambu and Ender, I run this before every prop:
Wash the plate. Finger oil kills PETG and makes PLA look sandy.
One sheet of A4 paper for Ender bed level. If it drags on all four corners and the center, stop tuning. Print.
First layer 0.28 mm even if the rest is 0.2. More squish, less peeling on big flat armor pieces.
PLA: 215–220 nozzle, 60 bed. If you see ridges, drop the Z offset 0.02, don’t crank temp.
Cosplay parts warp because the bed cooled while the walls were still shrinking. Keep the enclosure closed for the first hour even on PLA.
If it still fails, take a photo of the first layer, not the blob at hour 6. The blob is a symptom.
I sell print-ready prop STLs and a separate 1-hour live repair session. Files and repair are not the same product on purpose.
