I recently created a Viper helmet for 3D printing. Although it was a very clean and precise file, it turned out kind of sloppy after the print - and very expensive! It would have been cheaper to send the file to an actual helmet manufacturer and have them develop it the old fashioned way, probably. Thankfully, I did it for someone else who wanted the print for a costume, so no harm to my wallet.

I've considered for a long time to develop and print a better articulated, better scaled Lego mini figure. The more I think about it, though, the more I feel like the entire Lego system would need to be redesigned to a 1:1:1 ratio (in terms of a cubic brick with 1 stud). It's too much effort.