Darth Maul sculpted in ZBrush then retopologised his head in Maya to make a clean split between black and red for multi color printing. This was a one week project.
To substantially preserve materials on support, both arms were split and pins/keys were added to connect them to the body later.
Head printed separately with a dual extruder printer using black and red filaments.
Lightsber were split to print its parts in red and silver filaments.
Printer:
CreatBot DE PLus 3
Rafts:
Yes
Supports:
Yes
Resolution:
0.16 - 0.2
Infill:
5% - 20%
Notes:
This is a 300mm in height model. If you want to scale it down, I'd recommend combining all parts first and scale them down together, then separate them again.
I didn't get good result printing the head with less than 0.16 resolution.
Also, my dual head extruders are not perfectly aligned as a note, this is why I got a slight offset in the red color which is the second extruder.
To align and merge the black and red head parts in Simplify 3D:
Import both parts
Select them both and group them
From Edit menu, click on Align Selected Model Origins
In Cura:
Import both parts
Assign a color to each part
Click on Merge
When gluing the lightsber parts, if the 3 pieces are not perfectly straight, don't worry. Just wait until the glue is dry then blow it with a hairdryer and make it straight gently.
