Throughout history, chainmail armor has been an iconic component of a knight’s attire. Made up of thousands of interlocking metal rings, traditional chainmail provided flexible protection while allowing ease of movement. However, crafting chainmail by hand is an extremely laborious and time-consuming process.
With the rise of 3D printing technology, creators can now design and print their own chainmail much more efficiently. From cosplayers to LARP enthusiasts to history buffs, 3D printed chainmail opens up new possibilities for quickly and affordably producing customized armor.
In this post, we’ll explore the various methods and best practices for 3D printing your own chainmail creations at home.
Optimizing Chainmail Designs for 3D Printing
When designing chainmail for 3D printing, the first consideration is the size and shape of the rings. Smaller rings with an inner diameter of around 5mm tend to print more reliably. Larger rings may droop or fail to hold their shape.
The thickness of the rings also impacts the print quality. Thinner rings of 1-2mm thickness tend to print easier than thicker rings of 3mm or more. Thicker rings run the risk of inadequate fill resulting in weaker links.
The material choice also affects the quality of the print. More flexible materials like TPU can print smoother rings and hold up better over time versus rigid materials like PLA or PETG.
When modeling the chainmaildigitally, interconnected rings are preferred over separate links. This allows the pieces to print as one cohesive unit rather than attempting to assemble many tiny individual rings.
Ring Design Options
There are a few common design approaches when modeling chainmail rings:
- Solid Rings – Each ring is printed as a complete solid loop. This is the strongest option but also uses the most material.
- Spiral Rings – The rings are modeled as a continuous spiral. The spiral meets up with itself to form a closed loop.
- Overlapping Rings – The ends of the ring overlap each other slightly and are fused together. This saves material but may have a visible seam.
- Open Rings – The rings are designed as open bands that don’t fully close. Links can be manually closed after printing. This saves the most material but reduces strength.
3d Printed Chainmail Chain Patterns
With the ring design completed, the next step is arranging the rings into the desired chain pattern. Some popular weave types include:
- European 4-in-1 – This simple pattern has each ring linked with four others. It’s faster to print and assemble than more complex weaves.
- Japanese 6-in-1 – Also known as the Orioroi pattern, each ring connects with six others for a tighter weave and increased flexibility.
- Persian 8-in-1 – With eight connections per ring, this style is dense and elastic while still providing good protection. It mirrors historical examples.
- Box Weave – Rings linked in rows, with each ring connecting to four neighbors. Forms a flexible grid or “box” pattern.
- Dragonscale – Rings are arranged in overlapping rows resembling dragon scales. Provides complete coverage when layered.
3D Printing Techniques
Once you have your chainmail model ready, it’s time to start printing. Here are some useful tips for success:
- Print Vertically – Orienting chainmail upright minimizes the need for support material while allowing each ring to print fully before moving upward.
- Use Tree Supports – Tree supports can be easily detached from chainmail prints while providing stability during printing.
- Enable Sparse Infill – This produces a lightweight interior to conserve material on the many rings in your chain.
- Print Hotter and Slower – To prevent links from breaking, print around 210-220°C at 40-50mm/s. The extra heat and slower speed allows the links to fuse properly.
- Check Layer Adhesion – Ensure the print surface is clean so the initial layers adhere well. This prevents warping or detachment mid-print.
Post-Processing
Once printed, a bit of post-processing can help improve the look and durability of your chainmail.
- Remove Supports – Break away any tree supports gently to prevent damaging the rings. Needle-nose pliers can help reach small spaces.
- Sand Rough Edges – Lightly sandingsmooths any remaining print layers and removes support marks from ring surfaces.
- Close Open Links – Use pliers to close up any open links and complete the circuit of each ring.
- Add Finish – Spray paint, rub n buff, or patinas can protect, colorize, and weather your chainmail. Clear gloss coatings also work.
- Connect Separate Pieces – If you printed chain sections separately, open links on each end allow connecting them together.
- Rivet Closed Links – For extra strength, metal rivets can permanently close rings and prevent breakage over time with wear.
Advanced Printing Options
More advanced users can also try:
- Multi-Color Printing – Use color change gcode to produce rings of different colors for a more stylish and visible print.
- Flexible Filament – Filaments like TPU allow the chainmail to flex naturally while retaining impact resistance.
- Dissolvable Supports – Dissolvable filaments like PVA can print temporary supports inside rings that simply wash away after printing.
- Metal Plating – For authentic metal chainmail, electroplating can coat 3D printed parts in materials like copper, nickel, or silver.
Modeling and printing your own chainmail using these techniques opens up limitless possibilities. With the right designs and printing methods, creators can craft historically-inspired armor for costumes, props, displays, LARPing events, and more. As 3D printing technology advances, so too will the intricacy and durability of chainmail creations.
