Edge of Tomorrow Jacket Technology Suit

I Have started molding and casting. I will be doing this for all the final parts.
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I have done some testing, from left to right original, smooth on fetherlite, onyx, and aluminum cold casting powder
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I decided on the fetherlite with the aluminum casting powder.
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Some very cool research done the mounting system for the feet found.
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It looks like for the feet they used snowboard bindings with the back removed.
The closest on looks I could find where these.
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Amazing work !! A joy to follow this post . It's coming together very well , thank you for sharing , can't wait to see the final suit .
 
I have been looking for the hing for the thigh plate cover.
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Not being able to find the correct one i decided to make one in CAD. I will be ordering it thought shapeways, then casting and molding a set for the plate hinges.
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I have been looking into the function of the joints of the legs and hydraulics. To solve this i decided i needed to do 3d printed parts. I looked into cost and actually found it will cost me less for just this project to buy a 3d printer than to continue using my wood working tools just in materials The more i did the more i found that i would be worth it to just do it all 3d printed. So i have been using my cnc layout to give me direction in making STL files.
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I started printing some of the fist parts to get the idea how they will cast and mold.
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I looked at the finished surface and found the print lines to be not up to the standard i want i started testing finishes.
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I used bondo putty 907, Dupli-color primer filler, some sanding, and krylon gloss blue and the finish is actually better than my cnc parts so i will be continuing with this method in mind for the rest of the parts.
 
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I finished the molds for the attachment for the hydraulic hose(the hose is Thera-Band)
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I also got the mechanical parts all working together for the knee joint.
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Update on two things the flexible hip cover and the template for all the hydraulic rams.

Hip cover was done with a 3d printed injection type mold with Smooth-on Dragon Skin 10 NV and black silc pig dye.
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The hydraulic ram is done with aluminum tubes and then 3d printed additions to make them into the correct ram type. The Hydraulic hose attachment i molded and cold casted with aluminum.
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