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  1. Sonjou's Avatar
    Member Since
    Feb 2012
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    Feb 15, 2012, 2:50 PM - TDK Foam Pattern, Design, Costume Build. ( PIC Heavy) #1

    Hello everyone, First time here and poster. Been a lurker for awhile.

    A little bit about me. Name is Mark I work at a movie theatre and do a lot of movie promotions. I have been numerous heroes over the years some good costumes some not so good.

    This year i will be working on a Dark knight suit made with foam.

    But it is hard to find patterns online so by grabbing tons of reference images and some ideas from other foam builds I started making a pattern for TDK.
    As I make the pattern I will post more images then eventually the costume.

    I cannot take all of the credit though.

    I found the front Chest template somewhere and i cant remember who created or what forums it was on. (probably these) If it was anyone on here i will give you total credit.

    Edit*

    Found the person that made the chest pattern.

    Egon

    http://www.therpf.com/f24/dark-knigh...27/index2.html


    This is all a work in progress so bare with me as i try and complete all of this. i will post what I have done so far.
    ================================================== =


    Tools

    ================================================== =

    Dremel Tool (not sure if i will this)
    Bought from walmart $36



    Hot glue gun
    Bought from walmart $7





    Heated craft carver/pen thingy
    Bought from walmart $11





    Scissors(already owned)





    Sharpie (already owned)





    Knife (already owned)




    ================================================== =


    Material List

    ================================================== =

    Foam interlocking tiles 2x2 1/2" thick $0.99sqft
    Bought from http://www.foamtiles.com

    I got six tiles for a total of $24 Free shipping


    Flat side



    Ribbed side




    Cape 3 yards $8.00 per yd 3 yards plus shipping $33
    Bought From spandexworld




    Mesh Under Suit 3 yards $7.50 per yd plus shipping $32.50
    1571 Medium Poly Mesh
    Bought from Seattle Fabrics




    -----------------------------------------------------------------
    This is the chest and back, i haven't decided how I'm going to separate the pieces and put them together but this is the design so far.




    -----------------------------------------------------------------

    Next is the gauntlet.

    Now with these they are to scale for me and separated on two sheets . i just need to add a few more pieces to add to the elbow pad.

    I made a paper mock just to test the scale. so just some scotch tape and paper and scissors.


    -----------------------------------------------------------------

    Good for paper not foam








    ================================================== =

    paper tests

    ================================================== =







































    -----------------------------------------------------------------

    *Edit (new design for foam)


    ================================================== =


    Foam Templates

    ================================================== =


    Gauntlet











    Neck






    Shoulder














    Triceps, and straps








    Legs














    Abs
















    Chest








    Collar








    -----------------------------------------------------------------

    First cuts (no glue yet)


















    Questions comments all Appreciated. or if anyone has any patterns that I can edit or use would save me some time thanks.
    Last edited by Sonjou; Mar 11, 2012 at 1:20 PM.
  2. DJDARYO1982's Avatar
    Member Since
    Nov 2010
    From
    Cremona - Italy
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    46
    Feb 16, 2012, 3:19 AM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #2

    Very nice bro!!! how are you planning to do the cowl?? foam ?
  3. Sonjou's Avatar
    Member Since
    Feb 2012
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    Feb 16, 2012, 4:47 PM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #3

    Not foam i have an old batman mask probably rubies. I will modify it to make fit better.
  4. Sonjou's Avatar
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    Feb 2012
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    Feb 21, 2012, 1:25 PM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #4

    Updated first post with materials, and some new designs on the gauntlet.

    My previous Design worked for folding the paper and taping. but due to the thickness of the foam the edges are not needed.
  5. SantinoCasas's Avatar
    Member Since
    Oct 2011
    From
    Chicago, Illinois, United States
    Messages
    24
    Feb 21, 2012, 8:20 PM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #5

    Hey Mark this is looking great man, looking forward to seeing how this turns out.
  6. RPF Premium Member Berserk's Avatar
    Member Since
    Oct 2010
    From
    Australia
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    208
    Feb 21, 2012, 10:55 PM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #6

    I'm working on one of these at the moment, what are you looking at for the under mesh?
  7. Sonjou's Avatar
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    Feb 2012
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    Feb 22, 2012, 10:59 AM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #7

    Berserk said: View Post
    I'm working on one of these at the moment, what are you looking at for the under mesh?
    Still looking into that.
    I'm not going for accuracy. The people that are here at the promo will see and know that it is batman. so with that said.

    I'm looking for an inexpensive material. I got a swatch form one company but it looked good on the site. but when I got it the mesh pattern was way to small.

    so I found another company I have a swatch coming so hopefully it will be good.

    I will post the pictures and cost once I get it in.

    Also updated the top post with tools and there prices.
  8. Sonjou's Avatar
    Member Since
    Feb 2012
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    Feb 22, 2012, 5:07 PM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #8

    Updated first post,

    Added Neck pattern

    and neck paper test.
  9. ironspider is offline ironspider
    Feb 24, 2012, 3:56 AM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #9

    very nice work
  10. ironspider is offline ironspider
    Feb 24, 2012, 3:57 AM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #10

    joanns has a nice aqua mesh that will work for the undersuit
  11. Wookieefoot's Avatar
    Member Since
    Sep 2011
    From
    MN, USA
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    21
    Feb 24, 2012, 9:14 AM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #11

    Nice! Those heat knifes work great for cutting out the foam pieces. Wish I would have checked Walmart for one. I had to drive all over town to different hobby stores trying to find one.

    Looking forward to more, keep it up!
  12. Sonjou's Avatar
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    Feb 2012
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    Feb 28, 2012, 9:52 AM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #12

    Good to know they work well with it. haven't got anything done this week. busy at work and home. but prob tonight should have some more progress.
  13. Sonjou's Avatar
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    Feb 28, 2012, 9:27 PM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #13

    Update*

    Top post updated i got my fabric in for the mesh suit.

    Prices and length updated also.
  14. ironspider is offline ironspider
    Feb 28, 2012, 11:00 PM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #14

    very nice build
  15. Sonjou's Avatar
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    Mar 1, 2012, 10:21 AM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #15

    Thanks
  16. Member Since
    Jun 2008
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    743
    Mar 3, 2012, 11:21 AM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #16

    Sonjou said: View Post

    Edit*

    Found the person that made the chest pattern.

    Egon

    Dark Knight Foam/Styrene DONE with Pics - Page 2


    Nice build. You're linking to the hacked site, though. I'd change the link to therpf.com so others don't accidentally go there.
  17. Sonjou's Avatar
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    Mar 3, 2012, 2:11 PM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #17

    thanks for the heads up i didnt even realize it. thats the page i had bookmarked.
  18. Sonjou's Avatar
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    Feb 2012
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    Mar 7, 2012, 4:59 PM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #18

    Updated first post.

    Added patterns for shoulders and triceps, and straps.

    I made a paper test .

    I have not tried the pattern on foam yet. but i believe it should work.

    I started on the leg patterns, I hope to have paper tests and patterns up tomorrow.

    thanks
  19. Sonjou's Avatar
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    Feb 2012
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    Mar 8, 2012, 4:59 PM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #19

    Updated first post with leg patterns.
  20. Sonjou's Avatar
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    Feb 2012
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    Mar 9, 2012, 3:47 PM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #20

    Updated first post.

    Ab patterns, ab straps, Chest patterns.
  21. Sonjou's Avatar
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    Feb 2012
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    Mar 11, 2012, 1:19 PM - Re: TDK Pattern, Design, Costume Build. ( PIC Heavy) #21

    Updated collar/shoulder/chest pattern.

    and paper tests
  22. ugameenough is offline ugameenough
    Apr 26, 2012, 6:24 PM - Re: TDK Foam Pattern, Design, Costume Build. ( PIC Heavy) #22

    i think u should use 1 or 2mm foam sheets and double it up to make it bulky or make it in layers.. but what do i know lol jus sayin lol other than that lookin good.
  23. ugameenough is offline ugameenough
    Apr 26, 2012, 6:24 PM - Re: TDK Foam Pattern, Design, Costume Build. ( PIC Heavy) #23

    my bad u did layer it out lol sorry
  24. Member Since
    Jun 2009
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    May 22, 2012, 11:27 AM - Re: TDK Foam Pattern, Design, Costume Build. ( PIC Heavy) #24

    Those are some nice looking gauntlets!
  25. Member Since
    May 2012
    From
    Georgia
    Messages
    5
    May 22, 2012, 11:30 AM - Re: TDK Foam Pattern, Design, Costume Build. ( PIC Heavy) #25

    This is a sick pattern, I may use some of the ideas here to make a decent Robin or Nightwing costume!

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