Print the helmet with brim @ 0.10mm layer height (see 3MF file)
The hands need support below the repulsor!
The repulsors are very small and are made of a single bottom layer. This can make printing difficult.
Use print glue if necessary
After printing, apply alcohol to the repulsors and bend the PE sheet again and again
At some point it should be possible to remove the parts without deforming them
This trick worked for me the first time I tried it
Helmet V2.x:
Multicolor version:
Slide the head into the Helmet like described below
Sand/clean the visor
Push the visor in by first pushing it in at the top and then along the entire length
It should hold without glue, but you can also glue it from the inside
Iron Man is wearing the multicolor version in this picture and holds the closed version.
Helmet:
Check the inside to see if it has been printed cleanly and remove any filament debris that is sticking out
Has the brim been removed cleanly?
The elephant foot can cause the inner rim to be a little too narrow, just sand the inner rim down a little or work it with a knife
Slide the head into the helmet and press it in with gentle force on the chin
Hands:
If the repulsor does not fit into the hole in the hand, carefully widen the hole with a scalpel or similar
Apply small droplets of glue and glue in the repulsor.
The new shape makes the hand a little more rigid, but with a little careful force it can still be placed on the forearm. Make sure that there are no debris or brim on the forearm/hand. Otherwise you could break the hand!
If the repulsor is semi-transparent, simply paint it with a paint pen before or after gluing