I'm using a Prusa MK2.5S and MK3 to print the Iron Man MK85 suit in PETG with 2 perimeters & 7% rectilinear infill. I've gone down to 5% and up to 11% on a few parts but 7% has been just right for the majority for my parts.
I've gone with 1 perimeter and 10% on anything "structural" on my War Machine MK1.
Some more decorative parts are only 5%
I am using a .6mm nozzle though
That's interesting. What filament type, printer(s) did you use? How did sanding go with only 1 perimeter? Hand sand or palm/orbital sander for the large areas? Pictures?
Sanding not been a problem with either.
Not go to the sanding stage on War Machine yet, but I have done a First Order Snowtrooper (the helmet wasn't printed), nearly at the painting stage of a First Order Trooper
I do use a few coats of automotive 2K filler primer, so that will help make up any loss through sanding
3 perimeters 0 infill. 4 top 3 bottom. It's amazing and the prints are strong and fast
My comment on that would be weight.
I used a piece of my WM armour in S3D and looked the difference in weight between 1 outline and 10% vs 3 outlines and 0%
It was 150g difference for approx 1/6 of the chest, that's getting up to 1kg for the whole piece
You start adding that up and by the time you've done a whole suit, that's a lot of extra weight.
Yes, 3 outlines will be strong, but you have to balance strength vs weight and whether the part you're printing is going to be under stress when wearing it