I only get cracks when my printer is having issues, or my slicer profile is bad.
Every design has been test-printed successfully (that's how I take photos) and I have used several of these (including the dire wolf) for finished heads
Maim
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At 3-6 walls thick they shouldn't be brittle (they're 3 in some areas, supported by a framework of 5-6 wall thick reinforcement in other areas). If you're having issues with brittle/cracked prints in areas that are 3+ walls thick, you may be having extrusion issues or your filament may be humid (moisture causes most filaments to bubble and pop)
if you're worried you can also coat the inside in plasti-dip or similar material (which can sort of self-heal minor cracks)
Any ridged headbase will not be indestructible without being extremely thick/heavy (be it 3D printed, resin cast, or fiberglass/carbon-fiber) so if you want a base you can step on, you'll need to use foam.
I have seen them printed successfully in TPU, but I would not personally recommend it.
Generally TPU heads are designed to be thicker, so they can be printed as infill-only. I assume that helps with the heat issues (TPU bases can be hotter to wear than foam or PLA/PETG) and messiness of the material.
I'm sorry you're having issues with your printers or print settings, but I've successfully printed every headbase I sell with no issue (the sample photos are at-scale, successful prints.)
Every base will print successfully with a raft or large brim (depending on your bed surface), and the only base that will require support is the skulldog.
I probably won't be adding any new split heads for a while (I do have them for some of the sets). It makes the heads easier to print on smaller printers, which makes them more accessible for people who are new to printing (in most ways, that is GOOD) and I don't have time to teach a bunch of people how to use their printer or glue a head together- so I don't think I'll be adding any new split up bases until I have time to also make tutorials
probably won't add an Ender cut version any time soon
(not until I have time to make a tutorial pdf for putting them back together and printing them correctly)
if you want to cut it yourself, I just use meshmixer. It's free and it's popular, so there's a lot of resources on youtube etc for learning your way around it