Elysium Max Exoskeleton

Don't want to see this ad? Sign up for anRPF Premium Membershiptoday. Support the community. Stop the ads.

Don't want to see this ad? Sign up for anRPF Premium Membershiptoday. Support the community. Stop the ads.

01binary

Member
I successfully cast the chest plates this fall (see two posts ago), but after many casting attempts on hip bones this winter, I finally ran out of slurry. I can't order more because it would arrive frozen, resulting in permanent chemical damage.

Issues included areas that cooled too fast, porous surface, and pieces of the mold breaking off prematurely:

1586241553201440683.png


So, I am switching back to box casting. Here's the breakdown of the parts I have left to cast:

Shell casting with SuspendaSlurry
  • Hip Left
  • Hip Right
  • Chest Base
  • Shin Snockplate Left
  • Shin Shockplate Right
Box casting with UltraVest
  • Hip Bottom Connector
  • Spine Top
  • Spine Bottom
  • Spine Middle Left
  • Spine Middle Right
  • Foot Upper Shock Plate (2)
  • Foot Shock Plate (2)
I also started working on polished sheet metal bracelets to attach arm bones without using elastic belts or gauze (like in the movie).

8448651553201530455.png


The prototyping session:

3400071553201582350.png


1215411553201611048.png


The parts I uploaded to RSM RapidQuote:

9932511553201765527.png


9788151553201773732.png
 

joberg

Master Member
Looks very good of course...I don't think that anybody did such a project before on the RPF:cool::cool::cool: The bar you've set is way high(y)(y)
 

01binary

Member
Last week I finished two more molds for shin shockplates. The only other "required" part left is the chest plate, one of the biggest and coolest-looking parts of the exoskeleton. There are a bunch of optional parts I would like to cast as a stretch goal, notably the tiny details placed on the hands, the vacuum tube holders with light-up tubes, and some tech gribble for the face to complete the cyber ninja look.

Fig 1: Preparing to pour the second part of both two-part molds

3473561555601518355.jpg


Fig. 2: Finished making the first part of a two-part mold with 3D-printed model suspended in clay

5019651555601436038.png


Fig 3: Resulting two-part molds I will use for casting wax positives



Fig. 4: Resulting wax positives that will be shell-cast by adding 10 layers of ceramic shell and melting the wax out before pouring metal

3406241555601585622.png
 

01binary

Member
In the past 3 weeks I cast the remaining parts for the spine as well as shock plates/armor that will be attached to boots:

3551521555715771097.png


9109871555716556295.jpg


Just before that I cast two extra parts I was missing before, a shoulder connector with some extreme detail and an unsightly hip connector. One of the parts here is repeated above.

7608321555715955023.png


My sheet metal order of bent spine connectors and arm bracelets came in:

4661911555715852469.png


9753121555715869815.png


I decided I might as well make those in 2mm stainless steel after prototyping with paper and cardboard, since the cost of getting them done in a sheet metal shop was going to be high either way:

2832991555715928237.png
 

Don't want to see this ad? Sign up for anRPF Premium Membershiptoday. Support the community. Stop the ads.

joberg

Master Member
Wow, insane amount of work and skill to make that whole exo-S coming to life!!! Keep up the epic work:cool::cool::cool::cool::notworthy::notworthy::notworthy::notworthy:
 

01binary

Member
The past three weeks have been a living hell of trying to cast two large plastic parts with complex geometry and thin edges out of rubber. Today it ends!


7477551557800698304.png


4872241557800790245.png


2977821557800820099.png


7993601557800851551.png

9482751557800876319.png

6709271557800997470.png
 

01binary

Member
Thank you! Today I poured the last mold required to complete the project. There are some optional parts left to make molds for that I might do if I have time left before the Wasteland Weekend.


500021558390745339.jpg


8530581558390764457.jpg


9122731558390860083.jpg
 
  • Like
Reactions: JPH

Don't want to see this ad? Sign up for anRPF Premium Membershiptoday. Support the community. Stop the ads.

01binary

Member
Thank you dornigt! I'm continuing on with casting the chest & shin plates:


The original wax models:

1034435


Wax models dipped to build ceramic shell layers:

1034436


Baking the chest plate:

1034437


Baking shin plates (behind the chest plate)

1034438


Baked shells:

1034439


First attempt:

1034441


Second attempt:

1034440


Parts from both attempts together:

1034442
 

01binary

Member
I finished casting all the required parts mid-July and moved onto re-drilling & threading holes, filling imperfections with metal filler & modeling primer, polishing, and using a rotary tool to clean up small details. Can't believe how much work that really is - after a full day of drilling & filing I feel like I've been kicked around by bunch of people. There is no real clean up effort on the machined parts so it should go faster from here. I hope painting doesn't take months or I will miss the wasteland weekend deadline!

00.jpg


01.jpg


02.png


03.jpg


Lastly, I did a work-in-progress presentation on this project to a group of high school students at Pacific Northwest College of Arts:

3D Printing to Metal Casting: Making of Elysium Exoskeleton Prop

Screen Shot 2019-08-09 at 12.12.19 PM.png
 

Don't want to see this ad? Sign up for anRPF Premium Membershiptoday. Support the community. Stop the ads.

01binary

Member
Thank you! I don't know the full weight yet, because it has to be assembled first. All the bolts that hold it together actually weigh more than the suit by themselves.

This is the last week of painting before assembly and tuning.

01.png


02.png


03.png


04.png
 

joberg

Master Member
Another amazing update; seeing it painted makes a big difference in look already! Keep up the super duper work!!!
 

01binary

Member
Assembly this week, hoping to be done by EOD Thursday. It feels real, with pleasant weight, the coolness of metal, and the musical dings the pieces make when they touch each other, instead of dry clanking of plastic. The paint isn't perfect, but generally this is coming out as exactly as I envisioned.

01.png


02.png


03.png


04.png


05.png


06.png


07.png


08.png


09.png
 

Don't want to see this ad? Sign up for anRPF Premium Membershiptoday. Support the community. Stop the ads.

Don't want to see this ad? Sign up for anRPF Premium Membershiptoday. Support the community. Stop the ads.

Top