3D Printing Custom FPV Goggles Faceplates and Comfort Accessories

Your FPV goggles are the window through which you experience flight, and comfort directly impacts your flying performance. An ill-fitting faceplate that pinches your nose, leaks light, or fogs up during a critical maneuver isn’t just annoying — it can ruin your flying session. 3D printing enables custom faceplates and accessories that transform stock goggles into perfectly fitted, personalized equipment.

Why Replace the Stock Faceplate?

Stock goggle faceplates are designed for an “average” face that exists only in CAD software. Everyone’s facial geometry is unique — nose bridge height, cheekbone structure, eye depth, forehead angle. A faceplate that fits 80% of users leaves 20% with light leaks, pressure points, or a fit so uncomfortable they can’t fly for more than 15 minutes.

3D printed faceplates solve this. You can print faceplates in different widths (narrow, standard, wide), with different nose bridge depths (shallow for high bridges, deep for flat bridges), and in materials that conform to your face shape. TPU printed at 85A shore hardness flexes to match facial contours while maintaining enough structure to block light. The comfort difference between a stock foam pad and a custom-fitted TPU faceplate is immediately transformative.

Designing for Your Face

Several approaches exist for creating a custom-fit faceplate:

Method 1: Photogrammetry scanning. Use your smartphone to capture 30-50 photos of your face from multiple angles. Process them through free photogrammetry software (Meshroom, RealityCapture trial) to generate a 3D model of your face. Import this model into Fusion 360 or Blender, then design the faceplate interface surface to match your facial contours exactly. This method produces the best fit but requires comfort with 3D scanning workflows.

Method 2: Adjustable parametric designs. Several open-source faceplate designs on Printables include parametric Fusion 360 files. Adjust parameters like nose bridge width, cheek depth, and forehead angle, then export an STL matched to your facial measurements. Take measurement reference photos (profile and front-facing with a ruler) to dial in the parameters.

Method 3: Try-and-iterate. Print the “standard” faceplate at draft quality (0.3mm layer height, 2 perimeters) for test fitting. Identify pressure points (areas that feel too tight) and light leak areas (gaps between the faceplate and your skin). Modify the STL in mesh editing software (Meshmixer) or adjust the design and reprint. Three iterations typically produce an excellent fit.

Material and Print Settings

Faceplates require flexibility and skin-safe materials. TPU at 85A-90A shore hardness is the ideal choice — flexible enough to conform to facial contours, stiff enough to maintain its shape and block light. Varioshore TPU (which changes density based on print temperature) allows printing a faceplate that’s soft on the face-contact surface and firmer in the goggle-attachment area — a single-material, dual-hardness solution.

Print settings: 0.2mm layer height, 3 perimeters, 15% gyroid infill, 220°C nozzle temperature, 30-40°C bed temperature. Print the faceplate contact surface face-down on a textured PEI sheet for a comfortable matte finish against your skin. Use ironing on the top surface if the faceplate has flat sections visible when installed.

Post-processing: Lightly sand the face-contact surface with 400-grit sandpaper to remove any sharp layer lines. Wash with warm soapy water before first use. If you experience skin irritation (rare with TPU), apply a thin foam weatherstrip to the contact surface as a barrier layer.

Anti-Fog Fan Mounts and Ventilation

Goggle fogging is the enemy of FPV pilots flying in humidity or during physical exertion. When warm, moist air from your face contacts cooler goggle lenses, condensation forms — and you’re flying blind. 3D printed fan mounts solve this elegantly.

Design a fan mount that attaches to your goggle’s ventilation port (most FatShark-style goggles have a fan port on the top or side). Use a standard 25mm or 30mm 5V fan — the same size used in 3D printer hotend cooling. Power the fan from your goggle battery’s balance lead (a simple JST-PH to fan adapter) or a dedicated small 2S pack mounted to the goggle strap.

For goggles without a native fan port, design a clip-on fan housing that channels airflow through the existing ventilation slots. Position the fan to draw air through the goggles (pulling fresh air in) rather than blowing onto your face (which can dry your eyes). A PWM controller (small potentiometer) lets you adjust fan speed — full power for humid days, low power for gentle airflow in normal conditions.

Lens Protectors and Sun Shades

Goggle lenses are expensive and easily scratched. A 3D printed snap-on lens protector prevents damage when you toss your goggles in your bag. Print in PLA with a felt or microfiber lining (self-adhesive felt sheets from craft stores work perfectly). Design the protector to snap onto the goggle body without interfering with antenna mounts or head strap attachments.

For pilots flying in bright conditions, a 3D printed sun shade that extends the goggle housing around the sides of your face blocks peripheral light and improves perceived display contrast. Design with thin, flexible walls (1.5mm) that can conform to your face shape without creating pressure points. The shade attaches to the goggle body via the faceplate mounting holes.

Battery Holder and Cable Management

Goggle battery cables dangling and catching on your chair, your radio, or the ground is a constant annoyance. A 3D printed battery holder that clips to your goggle head strap keeps the battery secure and the cable tidy. Design options include:

• Rear counterweight holder: Mounts on the back of the head strap, balancing the goggles’ front weight and improving comfort during long sessions
• Side pouch: Clips to the side strap for easy access to the power button and charge port
• Cable management clips: Route the power cable along the head strap, preventing snags and keeping the cable from pulling on the goggle connector

For FatShark-style goggles with barrel jack power connectors, design a right-angle adapter that changes the cable exit direction to parallel with the strap rather than perpendicular. This simple change dramatically reduces cable snagging.

Antenna Organizer and Transport Case

Goggle antennas are awkward to store and transport — the patch antenna is bulky, the Omni antennas have delicate elements. A 3D printed antenna organizer clips both antennas securely during transport, preventing the SMA connectors from being bent or the antenna elements from being crushed. Design with dedicated pockets for a triple-feed patch (the large rectangular antenna) and two Omni antennas.

For complete protection, design a goggle transport case insert that fits inside a standard hard case (Pelican 1300 or similar). The insert cradles the goggles with the faceplate installed, includes antenna storage, and has a cutout for the battery. Print in PETG with 3 perimeters for durability. Add foam padding to the lid for additional protection.

Popular Compatible Designs

The FPV community has produced faceplates and accessories for most popular goggle models. Key resources:

• FatShark HDO/Dominator series: “FatShark Custom Fit Faceplate” on Thingiverse by user DroneComfort includes narrow, standard, and wide variants with parametric source files
• DJI Goggles 2/Integra: “DJI Goggle Fit Kit” on Printables includes the faceplate, battery holder, and cable management system
• Walksnail Avatar Goggles X: The “Goggles X Comfort Package” on Thingiverse bundles faceplate, fan mount, and lens protector
• Skyzone SKY04X: “Skyzone Faceplate V2” on Printables with adjustable nose bridge depth

Comfortable goggles mean longer, more enjoyable flying sessions. A few hours of printing and minor fitting adjustments will transform your FPV experience — and your face will thank you.

Looking for goggle-specific STL files? Browse our FPV Goggle Accessories Collection with pre-tested designs for 15+ goggle models, or submit your own design to share with the community.