(One Shot) Just finished up my Shang Chi Costume with a crapton of Resin Cast Details

Sithslayer78

New Member
So what follows is the build book for a cosplay contest I entered. I'm terrible at documenting builds in progress because almost all of my work happens in crunch time, but here's what I got. It's formatted to discuss the build in parts, with a sort of planning stage in the beginning. My goal here was to make the most accurate costume possible, using whatever was necessary to make it happen.

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1. Reference Conclusions (I wont post reference pics because they're all already in the definitive thread)
  • Movie (wasn't yet on Disney+ during initial construction)
    • Zipper Locations, 2 on the back 2 near the shoulders
  • RPF Thread
    • Confirmation on individual scales (See Quote)
    • A number of other items identified
  • BTS Footage
    • Costume design: Vest + Shirt/Sleeve combination
      • Very typical Marvel Design Language
    • Estimate on scale quantity (~14,000)
    • Prototype costumes, not all are hero props, some are stunt versions.
    • ID on at least one pair of pants (Levi’s red tag, not what is shown in promo shots or the red carpet mannequin)
  • Red Carpet Photos (@BrandondavisBD)
    • Missing sequin suggesting individual placement, confirmed in definitive reference thread
    • Shoes identified as Jordan Access "Black Gym Red", confirmed from multiple sources
    • Pants on red carpet missing in/outseam highlight
    • Tapered rings, seams present for split

2. Planning
  • Fabric Jacket
    • Frankenstein existing patterns from similar clothing
  • Add-on Rubber
    • Design, print, cast, glue
  • Rings
    • Design, print, post, paint, wire, mount
  • Staff
    • Cut Bamboo, dry, sand, deconstruct, wire, foam, paint/stain.
  • Procure
    • Jordans and Pants
  • Total time to completion: ~4 Months

3: Patterning and Fabric
  • Fabric was originally suspected to have an underpattern to it, potentially screen printed on
  • BTS footage showed the fabric to be a holographic dot pattern (Reference images below)

    oc6uWEPkAXyZddk4I2SXTI06yDLKbUGbM3zZsx1ZOJwzVwv-1g.png
    Ua2Ks92xlxS2A6KH-YSU88aqgCQ3BmjCmG2_neRco5ts_RRXaQ.png


  • Patterns frankensteined from paper patterns & Goodwill clothing
  • Sketches done on taped mannequin
    mgWeC4IYDTL2ak9fmBg4wG-8Y95BfPpazVxXFkTsRTvw74r8Kw.jpg
    HOpPpIylF4STEuHngV3Wuxd4IJ5WWjuHRJjPsjQ5KCN9pXFX3w.jpg

4. Materials Testing and Selection
  • Materials selected to ensure that adhesive bond was permanent to fabric
    • Sil-Poxy, Ure-Bond, Super Glue, and uncured material were used, only super glue was effective.
  • Clear silicone would neither adhere nor dye.
  • Urecoat was found to do both, and was readily available.
    • Given all of the materials surveyed, it is very likely that this is very close to the actual material used.
  • Black Neoprene was chosen for black details. Initial plan was to laser etch black silicone or other rubber sheet, none would adhere.
  • A number of small test molds were created
  • nzMcg7TpUtM49O8r88NIL1OqhWexFOVGHqsDThl9O3PgCdn3AA.png

5. Jacket Details, Black Rubber
  • Designed in Solidworks, split to fit print bed where necessary.
  • Negatives were produced for black rubber. Rigid mold.
  • Creature Cast liquid neoprene was poured into these molds. Corn starch was brushed into the molds to disrupt surface tension and remove bubbles.
  • mSLA was used for high fidelity and throughput
  • Leftover materials were used from previous projects (exact materials needed)
  • Long cure time due to air dry instead of chemical cure
  • 3Sflx1RClyY9jQa0_Oqxp8Qgv1JfpZg0IwEQcx_eHgcbYVGCsQ.png
    Ou7lOIA9dCzIPq0g89OVK65n1of4gkWKw-DwZEVD8RfEViyodA.png
  • HZ3hNsc6QMkDxM5IdtQlzQx6_ckby6ojqp0k7gi9UGS81MbOAA.png


 
Last edited:

Sithslayer78

New Member
6. Jacket Details, Red
  • Designed in Solidworks on 2D picture of template.
  • Positives were printed and used to create silicone molds
  • mSLA, again, was used for high fidelity and throughput
  • Cast and cured under pressure using Smooth-On Urecoat.
    • Laser cut shelves used inside of a paint pot for vacuum and positive pressure.
  • Rubber was tinted with black and red ink
  • Demolded and flash removed before laying out and gluing with super glue.
  • Multiple scale molds were created to increase throughput
  • Several attempts were made to get the color right
K7S4RNbcdm1JWybTpRwwo5C_nppcoGRzn61iNw9JEvzQcT1R4Q.png

NKoc9IwfCvx13yk3bhMq1mggbtzAJu2wPMXvcSpnZe6d-tTHXA.png

bHcHJUm69mSJj3Iv6TtfpbbcqWdHNk1uZ3oBB30NY11j_bJVGA.jpg



7. Jacket Details

  • Jacket lines painted using fabric paint then masked so that metallic red puff paint could be used for raised borders
  • Rubber and Vinyl details were then super glued on using flexible super glue
  • Additional thin black inner lining was added before final assembly
  • Sleeves have dark red lining
--zYwtCyzqHdkona0US-pylA72qKiXtcrN0ot0-6sICbrhqFNA.jpg
40jzuZQHpPxEABUmiaRuK-9tALFn8fpKWymt676lEPOJNZHlYg.png

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8. Rings
  • Modified 3D files
    • Cutouts for LED strips and diffuser
    • Scaled taper for arms
    • Magnet Cutouts and split
    • Split adjusted to allow magnets to act as physical keys
  • Initial Concepts:
    • Floating tensioned (compressive) ring assembly
      • Very complex, easily tangled
    • Floating hanged rings
      • Tested at Magfest, very unsuccessful.
  • Final design was to have the rings mounted on a PETG gauntlet to provide stability and spacing.
    • First two rings split in half to allow for hand to fit through
hQ0Krz6mY2sLQH9d7fiiWNwSk4exzEXfCyBTL4c7NdTY_UZNqw.jpg
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Sithslayer78

New Member
9. Staff
  • Bamboo grown in my backyard
  • Straight cut harvested, sun dried before sanding and staining
  • Original plan was to use foam for the dragon scales, but SLA 3D printed was a better option overall, if slightly more fragile
  • RGB LED strips inserted into either end, powered by a spliced vape battery and controlled wirelessly.

JUmNgWqYoEVXdtk-q3R-GPunKPaG3w0LfsqPCSVkKwNffjxKNw.png
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greenmachines

Active Member
This is insanely and amazingly detailed work. Applause all around. The techniques are more than enough to be proud of but I look at the tailoring and the fit after all that technical build and love the details to the actual clothing work.
 

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