3D Printed Iron Man Suit

This custom built Iron Man suit was built to capture my love for my favorite character - Captain America! Just kidding, Iron Man of course. This project took over a year to complete, and cost over $1000. It was a large commitment of both time and moeny, and I learned a lot along the way.

Supplies

(10-12) Filament: https://shop.zlabs3d.com/product/zlabs-pla/1?cp=true&sa=true&sbp=false&q=false

2 Part Adhesive: https://www.amazon.com/dp/B086XGBHH3?psc=1&ref=ppx_yo2ov_dt_b_product_details

Straps & Buckles: https://www.amazon.com/dp/B07X28HCLW?psc=1&ref=ppx_yo2ov_dt_b_product_details

Lights: https://www.amazon.com/dp/B071FC3P5W?psc=1&ref=ppx_yo2ov_dt_b_product_details

AA Battery Pack: https://www.amazon.com/Thicken-Battery-Holder-Standard-Connector/dp/B07WP1CYYW/ref=sr_1_3?keywords=8+pack+battery+holder&qid=1667518869&qu=eyJxc2MiOiIyLjUwIiwicXNhIjoiMi4wNCIsInFzcCI6IjEuNDkifQ%3D%3D&sr=8-3

LED Eyes: https://www.amazon.com/Batman-Decorations-Acrylic-Cosplay-Superhero/dp/B09NNW6H52/ref=sr_1_17_sspa?crid=2LQAUUUZ4QW12&keywords=led+eyes&qid=1667519248&qu=eyJxc2MiOiI1LjE4IiwicXNhIjoiNC42OCIsInFzcCI6IjQuNDEifQ%3D%3D&sprefix=%2Caps%2C5404&sr=8-17-spons&psc=1

Duralumen Paint: https://www.etsy.com/listing/926461074/duralumen-1-liter-bottle?click_key=4c35f3460601f6fe00c98f6ee6d96bf6c9f3f099%3A926461074&click_sum=b026329d&rec_type=ss&ref=landingpage_similar_listing_top-2

Duplicolor Metalcast Smoke Paint: https://www.amazon.com/Dupli-Color-EMC206007-Smoke-Metal-Anodized/dp/B00295T4JW/ref=asc_df_B00295T4JW/?tag=hyprod-20&linkCode=df0&hvadid=312128189269&hvpos=&hvnetw=g&hvrand=1563652127042478132&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9010791&hvtargid=pla-570217454857&psc=1

(3) Duplicolor Metalcast Red Paint: https://www.autozone.com/paint-and-body/specialty-paint/p/dupli-color-red-metalcast-paint-11oz/353489_0_0?spps.s=3441&cmpid=LIA:US:EN:AD:NL:1000000:GEN:10574827360&gclid=CjwKCAjwzY2bBhB6EiwAPpUpZuIGjsGYsFCNf2LvIOgR0SF-R9vb0DTAC7VrSkrZc_9w5DBxxWD7WRoCxtYQAvD_BwE&gclsrc=aw.ds

(2) Metallic Gold Paint: https://www.amazon.com/Rust-Oleum-Available-7710830-Metallic-11-Ounce/dp/B000Z8FGE2/ref=asc_df_B000Z8FGE2/?tag=hyprod-20&linkCode=df0&hvadid=216800360809&hvpos=&hvnetw=g&hvrand=14448685972878254334&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9010791&hvtargid=pla-352132807609&psc=1

(4) Behr Gloss Black Paint & Primer: https://www.homedepot.com/p/BEHR-PREMIUM-12-oz-Black-Gloss-Interior-Exterior-Spray-Paint-and-Primer-in-One-Aerosol-B000144/310275388?source=shoppingads&locale=en-US&&mtc=SHOPPING-RM-RMP-GGL-D24-024_003_SPRAY_PAINT-PB-BEHR_PROCESS_CORP-NA-SMART-NA-NA-MK496473300-9016896198-NBR-975-CON-NA-FY22_975&cm_mmc=SHOPPING-RM-RMP-GGL-D24-024_003_SPRAY_PAINT-PB-BEHR_PROCESS_CORP-NA-SMART-NA-NA-MK496473300-9016896198-NBR-975-CON-NA-FY22_975-71700000091531848-58700007706124599-92700069855024636&gclid=CjwKCAjwzY2bBhB6EiwAPpUpZn9HPajy9M_Wy-KBuTSyhcOEk4UDfxDTMolOQ261lIjesOR9AjCfphoC4HgQAvD_BwE&gclsrc=aw.ds

(6) Filler Primer: https://www.amazon.com/Rust-Oleum-Automotive-260510-12-Ounce-Sandable/dp/B006ZLQ4HQ/ref=asc_df_B006ZLQ4HQ/?tag=hyprod-20&linkCode=df0&hvadid=193168541182&hvpos=&hvnetw=g&hvrand=7492175687409134857&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9010791&hvtargid=pla-311135409811&psc=1

1K Clear: https://www.autozone.com/paint-and-body/specialty-paint/p/dupli-color-1k-clear-gloss-pearl-finish-paint-12oz/1176336_0_0?spps.s=3441&cmpid=LIA:US:EN:AD:NL:1000000:PBD:8362702311&gclid=CjwKCAjwzY2bBhB6EiwAPpUpZl48b16_fA5VHftZOt2d8zBiKUJnPfIuJYi_XlvxfdgCDYrW-6KUshoCKvcQAvD_BwE&gclsrc=aw.ds

10mm x 2mm Magnets: https://www.amazon.com/dp/B09V1CJ68G?psc=1&ref=ppx_yo2ov_dt_b_product_details

Frog Tape: https://www.amazon.com/FROGTAPE-1396747-Multi-Surface-Painting-PAINTBLOCK/dp/B004W913NS/ref=asc_df_B004W913NS/?tag=hyprod-20&linkCode=df0&hvadid=193168541182&hvpos=&hvnetw=g&hvrand=6742028621701003095&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9010791&hvtargid=pla-308556916491&psc=1

Undersuit: https://www.amazon.com/dp/B07R8M5KJV?psc=1&ref=ppx_yo2ov_dt_b_product_details

3D Armor files: https://www.do3d.com/product-page/iron-man-mark-lxxxv-armor-wing-mk-85-endgame-3d-model-project-5775-1

3D Helmet File: https://www.etsy.com/listing/1102234080/ironman-mark-85-helmet-3d-printable

Misc: AA Batteries, AAA Batteries, insulated wires, heat shrink, wire strippers, soldering equipment, 3d printer (I recommend a CR10S ProV2), sandpaper (I recommend 40, 100, 220, and 320 grit), palm sander, backpack (I recommend one with a chest strap to keep the parts from sliding), heat gun, velcro, hot glue gun, hot glue

Printing All of the Parts

First, download the files from the links above. You must then prepare all of the parts for printing in a slicer such as Ultimaker Cura. The printing part is one of the most expensive and time consuming parts of the project. Make sure you print these parts with thick walls and a high infill as you will be sanding them in the next step. I used 4 walls and 20% infill. I spent around 4 months printing the suit, so make sure you start early if you are looking to make one.

Sanding

Sanding is by far the most boring part of building this suit. When sanding, make sure you start my sanding the raw print with 40 and then 100 grit. Then, spray filler primer generously over the print and let it dry for a day. Sand the filler primer down by hand with 120 or 320 grit sandpaper. If you do not sand enough, layer lines from the print will show through the paint, which can be seen in the images above. If you want a super smooth surface you can do wet sanding with high-grit sandpaper.

Painting & Taping

Start off by painting a high gloss black primer over the filler primer. Tape off sections that will not be painted using frog tape, so that the black primer will not be peeled off. This is the second most time consuming part. Make sure that each tape piece is properly adhered before painting chrome over. The gloss black primer will allow the chrome paint to shine more brightly and give a better end product. Finally, spray the final coat, using the metalcast paint. For the gold parts, spray directly over the gloss black primer, not the chrome. Tape off each section once it's done until all colors are painted. Then, spray a 1k clear coat over everything to protect the paint.

Electronics

For the helmet, use a heat gun to form the led eyes to the faceplate. Put hot glue around the eyes to hold them in place. For the armor lights, use a soldering iron to melt out the areas where you want lights. Then, use hot glue to attach each light to the plastic. Combine all of the positive wires and attach them to the positive on the battery pack. Combine all of the negatives and connect them to the negative on the power pack. Finally, put in AA batteries to test the lights.

Assembly

Start by sewing the buckles onto cut straps. Using the two part adhesive, spray the activant onto the strap, and put the glue on the plastic. Press together and hold for a few seconds. Next, measure where the buckle needs to attach to the backpack. After measuring, sew and cut off the excess strap. Repeat this for all of the body pieces (abs, chest, back) and biceps. For the lower back, butt, and cod, use elastic straps and use the two part adhesive on each side, no buckles. For the biceps, sew buckles to the straps, and use the 2 part adhesive to attach the buckles to the biceps, back, and chest. No straps are needed for the forearms. For the hands, use elastic straps and 2 part adhesive to create all of the fingers and attach them to the back of the hand. Use elastic to connect the end of the back hand and to the front hand. On the side with the thumb, use velcro to close the hand. For the helmet, melt magnets into the dome, jaw, and side. Screw in helper arms to finish the helmet.

Putting It All Together

Finally, attach all of the parts together. Turn on the lights, and marvel (pun intended) at your creation! Putting the suit on takes 2 people, and can be done in under 5 minutes.