Making an Iron Man Suit

Saturday, April 30, 2016 | By | Add a Comment

Making an Iron Man Suit

Cosplay and semi-cosplay costumes can sometimes take a large amount of creative processes in order to achieve the desired end results of the designer.  3D printing is the favored process, since it is usually the most inexpensive and quickest way to create custom designed pieces.  Other processes, such as molding and casting can get to be somewhat pricey and time consuming, but they may also be necessary depending on the level of detail and expectations of the cosplayer.

The more complicated the costume is, the more detail and planning is necessary to create the costume in its entirity.  This often involves sketching the costume out to get a visualization of how the costume will look in different views on paper as well as creating scaled models of the completed costume design using a variety of materials such as wire frames, sculpting clay, manequins, plastics and many other materials to create your models.

If the costume involves moving parts or electrical configurations, then the designer must consider doing engineering tests and electrical layouts and testing as well.  Proper materials should be tested and used for different weight ratios and strength and durability depending on where each piece will be placed and the functionality of the piece.

These are just a couple of considerations to think about when creating a highly detailed and complicated costume.  Among those who create these cosplay costumes is James Bruton, a sci-fi and superhero fan who uses his Lulzbot TAZ dual-extruder 3D printer to create some very complex costumes ranging from an Iron Man suit to Android bipedal legs and even Star Wars replica parts.

In his free time, Bruton helps run the Southampton Makerspace and shares his builds on his website XRobots.  While he builds his complicated costumes using a variety of material types ranging from wood to plastic, the majority of the 3D printed parts used in his designs consist of ABS plastic and Ninjaflex.

The video above shows the processes involved in making an Iron Man suit with lighted configurations and engineered parts.  Many of the designer’s other costumes have much more complicated and technologically advanced components.

I hope this video gives you some inspiration on designing your own cosplay costume.  Thanks for reading and enjoy!

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Category: Cosplay, Gaming, Product Manufacturing

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