Iron Man "Suitcase Armor" with the help of rapid prototyping.

Discussion in 'Marvel Costumes and Props' started by chosetec, May 9, 2012.

  1. chosetec

    chosetec New Member

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    Here's a recently finished "Suitcase Armor" from Iron Man 2. I'll post some finished pictures first, and then include progress pictures.

    The suit is made of laser cut plastic, waterjet cut aluminum, and pleather with LED lighting for the eyes and repulsors. The faceplate flips up but not automatically, that's for a future version. It's a work in progress, I'm planning to replace all the pleather parts with articulated rigid components, add more gadgetry, and improve the general accuracy. I wanted to have something in time for Anime Boston and the Avengers showing (my friend Ger is Black Widow).

    The working time on this so far has been about three months, including design and CAD. Drawings and CAD screenshots to follow shortly.
     
  2. chosetec

    chosetec New Member

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    Pencil sketches

    Before I started with CAD I did a lot of sketches just to figure out the mechanics, especially of the rigid parts. I wanted to familiarize myself with the different components and how they might actually be hinged so that I could move comfortably. A lot of these designs ultimately weren't used but the brainstorm was helpful.

    This is a just a small batch of the total drawings I did over the months. I included a sketch I did of a custom Iron Man suit which I might try building someday.
     
  3. Mr Fett

    Mr Fett Sr Member

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    Nice work! :)
     
  4. Welmanshire

    Welmanshire Active Member

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    That is pretty cool. I don't think I have seen someone use aluminium for and iron man before.
     
  5. chosetec

    chosetec New Member

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    CAD Model

    Some pictures of the CAD Model I drafted up of the armor-to-be. I used Rhino3D, it's a good modeling program for engineering/design (and currently is downloadable as a free albeit expiring Beta for Mac users)

    I started this model by drawing a reference outline of my body, the dimensions of which I got using just a tape measure, ruler, giant calipers. Then I drew flat 2D views of the armor front, back and side views and used those views to model the 3D mesh. Then I unwrapped/flattened the mesh pieces and added tabs or attachment holes where needed so that I could rivet or otherwise connect the panels to each other.

    The biggest worry was that the helmet would end up too small - If I erred on the safe side I'd look like a bobble head. I measured my head as much as possible and crossed my fingers.
     
  6. chosetec

    chosetec New Member

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    Thanks! I work in a university machine shop, so there's a lot of aluminum scrap from student projects. As far as weight and machinability goes, it's a lot better than actual iron! There are some smaller parts where I used steel for better durability.

     
  7. chosetec

    chosetec New Member

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    Cutting pieces (Laser, waterjet)

    Most of the laser cutting I send to Ponoko.com while the waterjet is done at the shop I work at. Ponoko and shapeways are places you can send digital files and have them laser-cut (or 3D print) in a variety of materials including metal, cardboard, plywood and leather. This is really great if you have some complicated geometry and/or are in a rush.

    The plastic I had them use is PETG (the same as soda bottles). It comes thin and cheap, but a downside is that it's quite brittle when subject to shock.

    The aluminum and other metals are cut on a waterjet. This is like a high pressure hose connected to a motorized 2-axis system. The water entrains abrasive powder which wears away at the material being cut. It's quite versatile and can be used to cut through several inches of stone or metal, even.

    I don't have any pics of laser cutting since I got it outsourced, but here are some pictures of the waterjet and the parts.
     
  8. chosetec

    chosetec New Member

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    ASSEMBLE

    I made it so that most of the parts can be put together using rivets. I use pop rivets (like Klik-fast). If... I mean *when* I make another suit, I'll use rivets again but I'll use flush rivets so that they can be easily flattened and hidden.

    The helmet is held onto the head with some "headphone" looking thing. I call it "Beats by Dr. Stark". It isolates the sound from inside the helmet so you can hear pretty normally with the helmet on. I've had too much experience with helmets where all you hear is your own breathing.

    The chest RT parts were cut on the waterjet from various sheet metal parts, and glued together using lots and lots of superglue. The lights are tiny surface-mount LED's and the circuit is formed from copper foil, glued onto the plastic and soldered onto the LED's.

    After partial assembly, I sprayed the (clear) plastic parts crimson red.

    There were a lot of last-minute changes to the suit and I still had to hand-cut, tweak, and replace a lot of parts to make it work. Everything that didn't work this time around as a rigid component I used pleather instead. A word of caution: DON'T USE ADHESIVE VELCRO on pleather or other vinyls. It may work for a day or two, but after that, the adhesive reacts to form a nasty flowing, sticky mess. I felt like a bug in a sticky trap!

    The eyes were done with surface mount LEDs and the gloves were larger LEDs using champagne bottle covers as reflectors. Glove and arm armor was approximated with pleather panels.

    That's all the pics I have for now, stay tuned for upgrades and more.
     
  9. TheRealStark

    TheRealStark Active Member

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    Incredible work! Highly accurate - I can't wait to see the improved version!
    Very impressive. :)
     
  10. chosetec

    chosetec New Member

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    Thanks- nice work on the folding version. You've inspired me to think of that next.
     
  11. sjorsjo91

    sjorsjo91 Well-Known Member RPF PREMIUM MEMBER

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    Looks great can't wait to see more.
     
    Last edited: Jun 26, 2012
  12. king23j

    king23j New Member

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    This is overall sick! If you manage to cut the hands from aluminum, you will be about as close to an actual iron man as you can get! next mod is making this thing fly
     
  13. hellfire171

    hellfire171 New Member

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    pretty cool cant wait to see it done
     
  14. Moth

    Moth New Member

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    So freaking cool, man. Really top notch! Can't wait to see more work from you! :thumbsup
     
  15. GammaGreen

    GammaGreen Member

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    That's insane. Great work! It must feel great to get to the finish line!
     
  16. Jnasty8222

    Jnasty8222 Active Member

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    Looks just like the movie! Awesome!
     
  17. Cayce

    Cayce New Member

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    Impressive and Inspiring!
     
  18. shoujoaifan

    shoujoaifan New Member

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    That's so awesome!

    Thats so awesome one should compliment you.

    You could say that we should give you (puts on glasses) props.



    YEAAAAAAAAAAAAAAAAAAAAAAAAAAAAAH!!!



    ........my first post here ever, couldn't resist ^_^;;

    Awesome suit, keep up the good work!


    BTW, and I can understand if you say no to this, since you put so much work into them, and so many people would take credit for models, but if you didn't mind do you think you could share the CAD files once you're satsified with them (its an amazing suit already and you're STILL making it better! That's commitment) If they can be converted to pepakura that'll be awesome, but if not others could use shapeways and ponoko. Thanks!
     
  19. StarkTonyE

    StarkTonyE Member

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    MAN YOU REALLY MADE AWESOME BUILD!:)
     
  20. The Armorer

    The Armorer Well-Known Member

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    I would just like to say. You du man! That is all :p

    -The Armorer
     
  21. morcon1223

    morcon1223 Member

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    this is interesting. cant wait to see the finished armor
     
  22. tonystarks8100

    tonystarks8100 New Member

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    Thats some very nice stuff the Mark V is a very hard build
     
  23. hydin

    hydin Sr Member RPF PREMIUM MEMBER

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    * that looks great!!!!

    I'd be afraid to wear it though, looks incredibly "pinchy" :lol

    Can't wait to see how you are going to improve it. Already looks pretty badass now!
    Chris
     
  24. Jamesbengel

    Jamesbengel New Member

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    One of my favorite scenes from iron man 2 is the whiplash/iron man suitcase armor scene. The armor assending and unfolding onto tony stark was so cool.... I've considered building a suit of my own similar to this one...lthankyou for sharing your finished craft with rpf! Wonderful job and keep it up, inspiring.
     
  25. Rysjin7717

    Rysjin7717 Well-Known Member

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    Holy crap on a cracker!!! that is amazing awesome work there brah lildo has also some IM armors made out of metal you should check them out keep up th' good work:popcorn
     

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