Lion King Jr Musical: 3D Printed Lion Masks

This page covers how I designed and built 3D printed lion masks for our Lion King Jr. school production — from printer settings that keep masks lightweight, to paint colors by character, to two different strap systems for securing headpieces safely on young performers. Includes a full material list with links to every item used.

3D printed lion headpiece for The Lion King JR musical, finished in gold paint with sculpted facial details and layered brown fabric panels, designed to create a lightweight, reusable mask-style headpiece for youth theater productions.
Lion headpiece for The Lion King JR musical, featuring a 3D printed mask with painted facial details and a raffia-style mane, designed as a lightweight, stage-readable headpiece for youth theater productions.

SARABI HEADPIECE

SIMBA HEADPIECE

Display of a 2-point headpiece securing system for costumes featuring a lion mask and yellow satin cape, with front, side, and back views, labeled for application use.
Image showing a 3D printed lion headpiece for Simba, with instructions on how to secure it, including an adjustable baseball hat, chin strap, and optional neck strap.

2-POINT STRAP SYSTEM

2-POINT STRAP SYSTEM

Display of a 3-point headpiece securing system, featuring a baseball hat, chin strap, and neck strap, with photographs of the headpiece from front, back, and side views.

3-POINT STRAP SYSTEM

Material List:
⏺ 3D Printer: Bambu Lab A1 (Hint: make sure your printer settings create a “lighter” mask ie. reducing the infill density)
⏺ 3D Lion King JR Patterns (See more Lion King JR headpieces in my Pinterest board https://pin.it/4CvducCk7
⏺ Filament: PLA Matte

⏺Rust-Oleum Universal All Surface Metallic Spray Paint – Oil Rubbed 
⏺ Rust-Oleum 2X UltraCover Spray Paint – Khaki
⏺ Face Accents: Sharpie Acrylic brush pens

⏺ Base- baseball hat (remove bill)
⏺ Chin strap: elastic silicon band (black, tan, white)