Project Details

Cosplay: Pittsburgh Iron Man

From: Custom Design based on Marvel’s Iron Man (Mk7)

Materials: Foam, eco-friendly PLA 3D print filament on an Ender 3 Pro, spray primer, spray paint.

Finishing Touches: Motorized wireless helmet faceplate. LED lights. Four different arc reactor plates featuring the four major Pittsburgh sports teams (Penguins, Steelers, Pirates, Riverhounds).

Photographer: GCF Photography, Brandon Klinge, Photo4Food

Process & Features

This suit is mostly 3D printed using files created by Johan Joao. The neck is made with EVA foam for flexibility. Printed with eco-friendly PLA filament, Pittsburgh Iron Man was completed all on one machine, an Ender 3 Pro, after sizing to myself and cutting the pieces apart on multiple 3D designing programs.

Once printed, each piece was welded together with a soldering iron tip, then primed and sanded for paint. After paint is applied and set aside to dry and cure, electronics, triggered by buttons attached to an arduino system, were soldered together and installed. Four arc reactors were cast in resin to display the sports team logos to represent Pittsburgh, and a tribute decal to Jimmy Rich was printed and added on the right shoulder.


year created