When slicing 3D cosplay models, adjust infill percentage by function—use 10–20% for lightweight, non-structural parts (e.g., armor panels) and 30–50% for load-bearing pieces (e.g., prop handles, joint brackets).
Lower infill cuts weight and material for large, stress-free cosplay parts, while higher infill adds durability to pieces handled or impacted. Choose infill patterns like gyroid (strong, light) or grid (simple) instead of solid to balance strength and weight.
If you’re new, start with 15% infill for most armor—test a small section first. You can increase it later if the part feels flimsy, without wasting too much material.