Iron Man Build

It's been a long journey, but every journey must come to an end and I'm glad it's getting wrapped up.  When I first started this project I had started with just the helmet.  Finding out that it was possible, I had decided to make the full suit. I anticipated it only taking me 6 months, I was wrong.  A little over 4 years later I'm finally finishing up the suit which I'll probably tweak here and there and constaintly make minor improvements to, but for the most part it's done.  Most of the suit is hand made, the bigger parts like the helmet, chest, back and legs.  When it came down to the smaller parts, like the fingers and hands I learned 3D printing.  All the parts used to be Pepakura, but over time and as my skills improved in 3D printing, I've changed out a few parts to 3D print. These parts I designed myself.  Will I ever make a suit like this again?  Well, I do have casts/molds of everything, so we'll see.   I'd probly 3D print and only make helmets or use foam.  The suit turned out great, but I can tell you this, it's not very practical.  If you're building your own suit and have questions, feel free to ask me anything.  I've picked up many tricks/ideas over the years while building mine.  Enjoy!


Spring 2017 - Suit Debut, Wizard World Minneapolis May 6th


Winter 2017 - Helmet electronics


Fall 2016 - Finished paint job


Summer 2016 - Painting/Straps


Spring 2016 - Strapping/Hinges


Winter 2015 - Mold making


Spring 2015 - Finished prototype parts


Winter 2014 -Finished prototype parts


Summer 2014 - Building the legs, Bondo


Spring 2014 - Some 3D printed parts


Winter 2013 - Some 3D printed parts


Fall 2013 Pepakura and 3D print


Summer 2013 - Some 3D printed parts, Started learning 3D printing


Spring 2013 - Pepakura, Arms and ankles


Winter 2012 - Pepakura


Fall 2012 - Pepakura Helmet and Chest


Summer 2012 - The beginning, Pepakura Helmet