Uploaded December 2025 | Updated September 2026, 3 days ago
Han In Carbonite Life Size Build -Step by Step Build from Wood Frame, 3D Printing to Electronics
In this video, I show you how I built a full life-size Han Solo in Carbonite replica using a combination of woodworking, 3D printing, fiberglass, electronics, and detailed painting/weathering. If you’ve ever wanted your own Han in Carbonite, this step-by-step breakdown covers everything from the frame to the final metallic finish.
This is a complete prop build tutorial designed for Star Wars fans, DIY makers, cosplayers, and home workshop builders who love creating screen-accurate props. I walk through every major technique and material that went into this massive project so you can build your own or use the techniques in your next cosplay or display piece.
WHAT YOU’LL LEARN IN THIS BUILD
* How to construct the full-scale Carbonite chamber using wood and basic tools
* How to 3D print and finish the panel greeblies and Carbonite details
* Using fiberglass for strength, texture, and long-term durability
* Adding electronics and lighting to bring the panel to life
* Painting, weathering, and creating the iconic Carbonite frozen effect
* Final life-size assembly and full reveal
CHAPTERS
00:00 Introduction
04:27 Word Frame Assembly
10:29 Han Figure Assembly
12:01 Adding the Carbonite
14:54 Routing the Edge
15:14 Painting and Weathering the Frame and Han Figure
17:35 Painting Volvo Panels and Greebles
18:47 Assembling the Volvo Panels
24:50 Final Assembly
27:25 Final Prop and Electronics
ITEMS I USED IN THIS BUILD - All are affiliate links
Accurate Decal and Window pack for Han in Carbonite Build
bit.ly/449IQqL
HiC Wooden Box Kit for Carbonite build - 12 CNC cut 1/2" thick MDF pieces
bit.ly/4pn9LrC
Metal grill for hero panel of HiC build
bit.ly/4pURkdK
Han Solo in Carbonite Control Volvo panels
bit.ly/44bHUC7
Carbonite block - Used a lot of Greebles from this
bit.ly/48xPRCT
Elmer's Liquid School Glue, Washable, 1 Gallon, 1 Count - Great for Making Slime
amzn.to/44aT4qQ
Paint Brushes Set, 2 Pack 20 Pcs
amzn.to/4rEdCC9
Liquid Nails - 414607 LN-907 Extreme Heavy Duty Construction Adhesive (LN-907) 10 oz
amzn.to/4plVP17
DAP 12143 Fast'N Final, 1gal, white Lightweight Spackling, 1 gal
amzn.to/4pfcZgE
Apoxie Sculpt - 2 Part Modeling Compound (A & B) - 1 Pound, White/Stone White
amzn.to/4oBia9s
YONICO 13166 1/2-Inch Radius Round Over Edge Forming Router Bit 1/2-Inch Shank
amzn.to/3XFfXir
DEWALT Router, Fixed Base, 12-Amp, 24,000 RPM Variable Speed Trigger, 2-1/4HP, Corded (DW618)
amzn.to/48mp9yv
Insta-cure gap filling 2oz Bob Smith
amzn.to/4exIQUb
Bob Smith Industries Super Glue Accelerator
amzn.to/3TG9YYS
Liquitex BASICS Acrylic Paint, 250ml (8.5-oz) Tube, Mars Black
amzn.to/47mj9oI
Rust-Oleum 260510 Stops Rust Automotive 2-in-1 Filler & Sandable Primer Spray, 12 oz, Gray
amzn.to/48TQBDN
Rust-Oleum Metallic Flat Soft Iron - Wood Shell
amzn.to/4pkBjxB
Rust-Oleum Metallic Flat Antique Nickel
amzn.to/4oHvYj1
Rust-Oleum 2X Ultra Cover Paint+Primer Flat Black
amzn.to/48x9Mlu
Aluminum Roll Flashing, 6'' x 50' Metal Roofing Roll for Roof and Garden
amzn.to/48U2uJS
Dupli-Color Chrome
amzn.to/44LCUEn
ELECTRONICS
FETT-TRONICS is unfortunately closed.
DeepLee Filament- Love this stuff. Cheap and dependable.
amzn.to/4l6Haod
____________________________________________
Check out my 3D Printing Courses on Udemy ➜
3D Resin Printing: From Star to Finish
bit.ly/2ZeIBbN
3D Printing: From Start to Finish
bit.ly/2Nu91Uh
How to Make Money With Your 3D Printer
bit.ly/3Kl1Ern
Design Awesome Graphics For Social Media with Canva
bit.ly/2ZhvJly
Interested in FDM 3D Printers?
____________________________________________
ELEGOO RESIN PRINTERS
ELEGOO Saturn 4 Ultra 16K Resin 3D Printer
I love this printer!
amzn.to/3Gl0K0V
________________________________________________
Some Additional Items you will want to consider for Resin 3D Printing ➜
Resin - amzn.to/2GfHUcH
Disposable Gloves - amzn.to/2SqG7Uu
Plastic Spatula - amzn.to/30vuX5c
Metal Spatula - amzn.to/33tYUoc
Isopropyl (IPA) - amzn.to/3jyATlm
Pickle Container - amzn.to/3cX3fDv
Funnel - amzn.to/3isSLgo
Paint Filters - amzn.to/2HP3LI8
Lunch Tray - amzn.to/2Snt9a0
________________________________________________
Twitter ➜ twitter.com/3DPrintedProps
Instagram ➜ https://www.instagram.com/3dprintedpr...
Facebook ➜ facebook.com/3DPrintedProp
YouTube ➜ youtube.com/3dprintedprops
#3DPrinting #HIC #HanSoloInCarbonite #HanInCarbonite #StarWarsBuild #StarWarsProp
#CarboniteBuild
Han In Carbonite Life Size Build -Step by Step Build from Wood Frame, 3D Printing to Electronics
In this video, I show you how I built a full life-size Han Solo in Carbonite replica using a combination of woodworking, 3D printing, fiberglass, electronics, and detailed painting/weathering. If you’ve ever wanted your own Han in Carbonite, this step-by-step breakdown covers everything from the frame to the final metallic finish.
This is a complete prop build tutorial designed for Star Wars fans, DIY makers, cosplayers, and home workshop builders who love creating screen-accurate props. I walk through every major technique and material that went into this massive project so you can build your own or use the techniques in your next cosplay or display piece.
WHAT YOU’LL LEARN IN THIS BUILD
* How to construct the full-scale Carbonite chamber using wood and basic tools
* How to 3D print and finish the panel greeblies and Carbonite details
* Using fiberglass for strength, texture, and long-term durability
* Adding electronics and lighting to bring the panel to life
* Painting, weathering, and creating the iconic Carbonite frozen effect
* Final life-size assembly and full reveal
CHAPTERS
00:00 Introduction
04:27 Word Frame Assembly
10:29 Han Figure Assembly
12:01 Adding the Carbonite
14:54 Routing the Edge
15:14 Painting and Weathering the Frame and Han Figure
17:35 Painting Volvo Panels and Greebles
18:47 Assembling the Volvo Panels
24:50 Final Assembly
27:25 Final Prop and Electronics
ITEMS I USED IN THIS BUILD - All are affiliate links
Accurate Decal and Window pack for Han in Carbonite Build
bit.ly/449IQqL
HiC Wooden Box Kit for Carbonite build - 12 CNC cut 1/2" thick MDF pieces
bit.ly/4pn9LrC
Metal grill for hero panel of HiC build
bit.ly/4pURkdK
Han Solo in Carbonite Control Volvo panels
bit.ly/44bHUC7
Carbonite block - Used a lot of Greebles from this
bit.ly/48xPRCT
Elmer's Liquid School Glue, Washable, 1 Gallon, 1 Count - Great for Making Slime
amzn.to/44aT4qQ
Paint Brushes Set, 2 Pack 20 Pcs
amzn.to/4rEdCC9
Liquid Nails - 414607 LN-907 Extreme Heavy Duty Construction Adhesive (LN-907) 10 oz
amzn.to/4plVP17
DAP 12143 Fast'N Final, 1gal, white Lightweight Spackling, 1 gal
amzn.to/4pfcZgE
Apoxie Sculpt - 2 Part Modeling Compound (A & B) - 1 Pound, White/Stone White
amzn.to/4oBia9s
YONICO 13166 1/2-Inch Radius Round Over Edge Forming Router Bit 1/2-Inch Shank
amzn.to/3XFfXir
DEWALT Router, Fixed Base, 12-Amp, 24,000 RPM Variable Speed Trigger, 2-1/4HP, Corded (DW618)
amzn.to/48mp9yv
Insta-cure gap filling 2oz Bob Smith
amzn.to/4exIQUb
Bob Smith Industries Super Glue Accelerator
amzn.to/3TG9YYS
Liquitex BASICS Acrylic Paint, 250ml (8.5-oz) Tube, Mars Black
amzn.to/47mj9oI
Rust-Oleum 260510 Stops Rust Automotive 2-in-1 Filler & Sandable Primer Spray, 12 oz, Gray
amzn.to/48TQBDN
Rust-Oleum Metallic Flat Soft Iron - Wood Shell
amzn.to/4pkBjxB
Rust-Oleum Metallic Flat Antique Nickel
amzn.to/4oHvYj1
Rust-Oleum 2X Ultra Cover Paint+Primer Flat Black
amzn.to/48x9Mlu
Aluminum Roll Flashing, 6'' x 50' Metal Roofing Roll for Roof and Garden
amzn.to/48U2uJS
Dupli-Color Chrome
amzn.to/44LCUEn
ELECTRONICS
FETT-TRONICS is unfortunately closed.
DeepLee Filament- Love this stuff. Cheap and dependable.
amzn.to/4l6Haod
____________________________________________
Check out my 3D Printing Courses on Udemy ➜
3D Resin Printing: From Star to Finish
bit.ly/2ZeIBbN
3D Printing: From Start to Finish
bit.ly/2Nu91Uh
How to Make Money With Your 3D Printer
bit.ly/3Kl1Ern
Design Awesome Graphics For Social Media with Canva
bit.ly/2ZhvJly
Interested in FDM 3D Printers?
____________________________________________
ELEGOO RESIN PRINTERS
ELEGOO Saturn 4 Ultra 16K Resin 3D Printer
I love this printer!
amzn.to/3Gl0K0V
________________________________________________
Some Additional Items you will want to consider for Resin 3D Printing ➜
Resin - amzn.to/2GfHUcH
Disposable Gloves - amzn.to/2SqG7Uu
Plastic Spatula - amzn.to/30vuX5c
Metal Spatula - amzn.to/33tYUoc
Isopropyl (IPA) - amzn.to/3jyATlm
Pickle Container - amzn.to/3cX3fDv
Funnel - amzn.to/3isSLgo
Paint Filters - amzn.to/2HP3LI8
Lunch Tray - amzn.to/2Snt9a0
________________________________________________
Twitter ➜ twitter.com/3DPrintedProps
Instagram ➜ https://www.instagram.com/3dprintedpr...
Facebook ➜ facebook.com/3DPrintedProp
YouTube ➜ youtube.com/3dprintedprops
#3DPrinting #HIC #HanSoloInCarbonite #HanInCarbonite #StarWarsBuild #StarWarsProp
#CarboniteBuild
