Iron Man Power Suit #19 | From Foam to Fiberglass | James Bruton

This is a video of the entire process for moulding my foam Iron Man costume parts and casting rigid copies which can then be cleaned up/sanded/filled etc.

The biggest challenge making your own Iron Man power suit - that you can actually wear! – is how much detail. Every expects it to look accurate in terms of colour and shaping, and if you’re going to get inside it latches, strapping and so on is a must but… what else? Do you motorise the faceplate? How much lighting and depth do you give the unibeam? What kind of flexibility and motion do the knees, knuckles and neck need? Well, hopefully you’ll agree I went all out on this Iron Man build. Let me know what you think in the comments below.

① GENIUS

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Huge thanks to my patrons, without whom my standard of living would drastically decline. Like, inside out Farm Foods bag decline. Plus a very special shoutout to Aleph Objects, Inc who keep me in LulzBot 3D printers and support me via Patreon. https://www.lulzbot.com/

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② XROBOTS

Former toy designer, current YouTube maker and general robotics, electrical and mechanical engineer, I’m a fan of doing it yourself and innovation by trial and error. My channel is where I share some of my useful and not-so-useful inventions, designs and maker advice. Iron Man is my go-to cosplay, and 3D printing can solve most issues - broken bolts, missing parts, world hunger, you name it.

XRobots is the community around my content where you can get in touch, share tips and advice, and more build FAQs, schematics and designs are also available.

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The majority of the music and SFX used in my videos is from Epidemic Sound http://share.epidemicsound.com/xrobots