GlitchTech
Active Member
Original build thread for suit
Original build thread for gun
Original build thread for helmet
This project was a MAJOR challenge, and I learned a ton along the way about several different new skills. I'd estimate about 150 hours went into designing and building the full suit, plus dozens more hours of 3D printing, waiting for paint to dry, etc.
Flash Suit
Materials used: Spandex, Peltex stabilizer, spacer mesh, yoga mat, ribbon, Velcro, Aleene's Flexible Stretchable Fabric Glue, E6000, Apoxie Sculpt, vacuformed plastic
The shoe cover and glove patterns were created by "fabric" draping with butcher paper, and weren't based on any existing pattern. The jacket and pants were based on existing but heavily modified patterns. The dark gray sections on the jacket were one of the trickiest parts, as that's a yoga mat! In the movie, the costume designers actually sprayed layers of plastic onto fabric to get the texture they wanted, so this is as close as I could get - but it was a challenge to run it all through the sewing machine.
The armored pieces were made from Apoxie Sculpt and then vacuformed with a vacuform we made just for this costume. You can see it in the last picture above. The armor was then attached to the spandex with E6000.
Flash Gun
The flash gun was designed in SketchUp and printed on a Makerbot Replicator Dual-strusion with ABS plastic. The grips are 3D printed rubber, called Ninjaflex. The electronics are all custom built and have custom programming to make the lights on the sides "spin" and the light in the front "charge up", and the whole thing is powered by a rechargeable battery.
One of the VFX artists from the film saw the build on Thingiverse, and is commissioning his own since "your gun is such a great reproduction of the real one (which I held!), I would love to put it on my wall of movie mementos." I about fell over when I read the email!
Helmet
This was my first time sculpting and casting something larger than a simple gem. It's not perfect, but I'm proud of it! To make sure it would fit my head, we made a plaster head cast and used plasticene clay to sculpt the helmet. The mold is made from Rebound 25 and the helmet is cast from Smooth-Cast 320. Hours and hours of sanding and filling ensued. The top of the head is lined with leftover yoga mat for comfort, and the top of the head attaches to the jaw piece via clips above the ears. The decal on the back was printed on vinyl by a friend, the grilles on the sides and back are made of specially cut metal, and the clear visor was vacuformed.
Proof! (Sorry for the terrible selfie, there's no one around to help me take a better one.)
Original build thread for gun
Original build thread for helmet
This project was a MAJOR challenge, and I learned a ton along the way about several different new skills. I'd estimate about 150 hours went into designing and building the full suit, plus dozens more hours of 3D printing, waiting for paint to dry, etc.
Flash Suit
Materials used: Spandex, Peltex stabilizer, spacer mesh, yoga mat, ribbon, Velcro, Aleene's Flexible Stretchable Fabric Glue, E6000, Apoxie Sculpt, vacuformed plastic
The shoe cover and glove patterns were created by "fabric" draping with butcher paper, and weren't based on any existing pattern. The jacket and pants were based on existing but heavily modified patterns. The dark gray sections on the jacket were one of the trickiest parts, as that's a yoga mat! In the movie, the costume designers actually sprayed layers of plastic onto fabric to get the texture they wanted, so this is as close as I could get - but it was a challenge to run it all through the sewing machine.
The armored pieces were made from Apoxie Sculpt and then vacuformed with a vacuform we made just for this costume. You can see it in the last picture above. The armor was then attached to the spandex with E6000.
Flash Gun
The flash gun was designed in SketchUp and printed on a Makerbot Replicator Dual-strusion with ABS plastic. The grips are 3D printed rubber, called Ninjaflex. The electronics are all custom built and have custom programming to make the lights on the sides "spin" and the light in the front "charge up", and the whole thing is powered by a rechargeable battery.
One of the VFX artists from the film saw the build on Thingiverse, and is commissioning his own since "your gun is such a great reproduction of the real one (which I held!), I would love to put it on my wall of movie mementos." I about fell over when I read the email!
Helmet
This was my first time sculpting and casting something larger than a simple gem. It's not perfect, but I'm proud of it! To make sure it would fit my head, we made a plaster head cast and used plasticene clay to sculpt the helmet. The mold is made from Rebound 25 and the helmet is cast from Smooth-Cast 320. Hours and hours of sanding and filling ensued. The top of the head is lined with leftover yoga mat for comfort, and the top of the head attaches to the jaw piece via clips above the ears. The decal on the back was printed on vinyl by a friend, the grilles on the sides and back are made of specially cut metal, and the clear visor was vacuformed.
Proof! (Sorry for the terrible selfie, there's no one around to help me take a better one.)
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