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We Are Iron Man

3D Printed Iron Man Suit: The Most Incredible Projects

Picture of Benjamin Goldschmidt
by Benjamin Goldschmidt
Feb 10, 2020
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Suit up with this list of awesome 3D printed Iron Man suits! You're sure to become the next genius, billionaire, playboy philanthropist.

3D Printed Iron Man Suit Models

Is 3D Printing Suitable?

Many of Iron Man's printed parts are similar to War Machine, which is also 3D printable
Many of Iron Man's printed parts are similar to War Machine, which is also 3D printable (Source: DaDave via Thingiverse)

Ever since 3D printing became popular, Marvel fans have been working on ways to 3D print their very own Iron Man suits.

It turns out that, with enough time and effort, this is indeed possible. However, with so many options on the table, one must decide which version they want to print.

In this article, we’ve compiled some of the best builds from the beginning of the franchise to the end, to suit all your needs (pun totally intended). In doing so, we’ve tried to cover some of the following finer points:

  • Which movies do the suits appear in?
  • Who made the suits?
  • How was it printed?
  • What post-processing was done?
  • How much material did it take to build?
  • Is it ready to be worn for a cosplay costume?

If you like what you see but don’t have the setup to get it done yourself, consider using a 3D printing service. With Craftcloud, the 3D printing and price comparison service from All3DP, you’ll instantly find the best price and provider for your needs, with no additional fees!

In the meantime, suit up and get ready for some great builds!

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3D Printed Iron Man Suit Models

MK6

This Iron Man MK6 suit is a relatively accessible build from Thingiverse
This Iron Man MK6 suit is a relatively accessible build from Thingiverse (Source: DaDave via Thingiverse)

This Iron Man MK6 suit is the most accessible on our list, as it can be found on Thingiverse. Conveniently, there are many videos that show the suit in action, including a great dance routine.

Seen in both Iron Man 2 and The Avengers, the suit was successfully printed by the designer in PLA on a Prusa i3 printer. Finishing required sanding, painting, and extensive electronics integration to get it just right. In addition, it took at least 20 kilograms of material.

Next to the full suit, the design contains a battle-damaged mask in case you want your Iron Man to look less than pristine at the next convention. Like many of the builds on our list, the maker admits that this isn’t the most comfortable costume to wear, due to the Iron Man design itself, but on the other hand, it still looks amazing.

  • Who made the suit? DaDave
  • Where to find it? The files are available for free at Thingiverse
  • How was it printed? This design was printed with a Prusa i3 in PLA.
  • What post-processing techniques were used? Sanding, painting, and electronics integration were used in this build.
  • How much material did it take to create the suit? More than 20 kilograms
  • Which movie does this appear in? Iron Man 2 and The Avengers
  • Is it cosplay-ready? As has been said on the Thingiverse listing, “It looks great, but it is not comfortable.” Nevertheless, it was still clearly worn for a cosplay.

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3D Printed Iron Man Suit Models

MK7

The MK7 suit appeared in the Avengers and Iron Man 3
The MK7 suit appeared in the Avengers and Iron Man 3 (Source: Joe Toys)

This Iron Man MK7 costume by Joe Toys is the extremely recognizable suit from the Avengers movie. Created and sold by Joe Toys, it’s produced on standard FDM 3D printers using 25 kilograms of PLA. In terms of post-processing, like the other suits on our list, it took a significant amount of sanding and painting with automobile paint.

Unlike some of our larger costumes, this costume is meant to be worn to cosplay events with a handler for costume assistance. It comes in at $2,250 for the full costume without electronics or painting. For full electronics integration and painting the suit tops out at $4,400.

  • Who made the suit? JoeToys
  • Where to find it? The premade suit costs $2,250 at JoeToys
  • How was it printed? The suit is printed with PLA using a standard FDM printer.
  • What post-processing techniques were used? For the full suit, sanding and painting with automobile paint are used as well as the add-ins for the motorized parts of the suit.
  • How much material did it take to create the suit? 25 kg of PLA
  • Which movie does this appear in? The Avengers
  • Is it cosplay-ready? Yes. These costumes are custom designed and meant to be worn at cosplay events, particularly if the cosplayer has assistance or a handler.

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3D Printed Iron Man Suit Models

MK45

This Iron Man MK45 suit is comfortable to wear, when printed with flexible joints
This Iron Man MK45 suit is comfortable to wear, when printed with flexible joints (Source: Do3D)

This Iron Man MK45 suit, which appeared in Avengers: Age of Ultron, is a great take on the MK45 design. One of the most amazing aspects of this suit is that its lightweight compared to others while still maintaining a wearable nature. In addition, the files for this suit are only $199.

This suit was printed in PLA (along with some flexible filament for joints) on standard FDM printers. It does take a significant amount of sanding, priming, and painting to get it to this level, but coming in at only 12 kilograms of material, it’s the lightest suit on our list by far. With this suit, you’ll be jumping for joy as you walk into the next convention in true Tony Stark fashion.

  • Who made the suit? Do3D
  • Where to find it? The files are available for $199 at Do3D
  • How was it printed? The suit was printed with PLA on standard FDM printers.
  • What post-processing techniques were used? Sanding, priming, and painting with automobile paint
  • How much material did it take to create the suit? 10 to 12 kilograms of material, including support structures
  • Which movie does this appear in? Avengers: Age of Ultron
  • Is it cosplay-ready? Yes, if the joints are printed with a flexible material. According to Do3D, you can even dance in the costume!

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3D Printed Iron Man Suit Models

Hulkbuster

This partially 3D printed Hulkbuster suit is almost beyond words
This partially 3D printed Hulkbuster suit is almost beyond words (Source: James Bruton via YouTube)

Originally prototyped out of wood and cardboard, this incredibly impressive Hulkbuster suit is the Iron Man cosplay of our dreams.

The original Hulkbuster was designed by Tony Stark to keep the Hulk in check. He had teams of engineers to help source and manipulate the strongest metals. Meanwhile, the designer of this suit, James Bruton, had to make do with more traditional cosplay materials, such as styrene sheets, electronics, sheet metal, and foam.

In terms of post-processing, this costume required sanding, painting, and heat forming to get the shape for various parts that required a molded look. While it isn’t clear how much material was used to build the suit, it took many hundreds of pieces to put together, in a variety of materials (as listed before). Thankfully, the costume is cosplay ready and was easy enough to wear and still be functional for Defcon 5.

  • Who made the suit? James Bruton
  • Where to find it? (Not available)
  • How was it printed? Some of the Hulkbuster was 3D printed with ABS material on a Lulzbot 3D printer, however, a large portion of it was also made from Ninjaflex, foam, metal, styrene sheets, and electronics for full functionality.
  • What post-processing techniques were used? Sanding, painting, and heat forming
  • How much material did it take to create the suit? This costume took many hundreds of pieces to put together in a variety of different materials, however, the overall amount of 3D printed material is unknown.
  • Which movies does this appear in? Avengers: Age of Ultron
  • Is it cosplay-ready? Yes, it was fully functional during Defcon 5.

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3D Printed Iron Man Suit Models

Adam Savage's Titanium MK2

This titanium Iron Man suit can actually fly
This titanium Iron Man suit can actually fly (Source: Adam Savage's Tested via YouTube)

Topping out at the most impressive on our list, this build is a collaboration between Adam Savage and the Colorado School of Mines, who together managed to create a titanium (Ti64) 3D printed Iron Man suit that can actually fly.

This MK2 suit, found in the first Iron Man film, was printed with a DMLS additive manufacturing machine called the EOS M 400-4. It uses lasers to fuse the metal together layer by layer.

As you can probably imagine, the post-processing on this suit was extreme. Everything had to be done by hand, from bolting and riveting parts together to wiring up the Iron Man suit for flight. And that doesn’t even mention the finishing paint job that looks like it walked right out of the movie itself.

According to Interesting Engineering, the build required more than 300 titanium parts to be 3D printed. Though the exact amount of titanium is unknown, the entire setup weighed under 20 pounds in order to ensure it could fly. As for cosplay readiness, we wouldn’t recommend wearing this suit to the next convention; despite its relatively low weight, it wouldn’t be the most comfortable thing to wear.

  • Who made the suit? Adam Savage in collaboration with the Colorado School of Mines
  • Where to find it? (Not available)
  • How was it printed? It was printed on a DMLS 3D printer using a titanium alloy (Ti64).
  • What post-processing techniques were used? Bolting, riveting, gluing, casting, wiring, as well as painting the final suit
  • How much material did it take to create the suit? It took over 300 parts and weighed just under 20 pounds
  • Which movies does this appear in? Iron Man
  • Is it cosplay-ready? According to Richard Browning, “It feels like wearing a massive wetsuit.”

(Lead image source: James Bruton via YouTube)

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License: The text of "3D Printed Iron Man Suit: The Most Incredible Projects" by All3DP is licensed under a Creative Commons Attribution 4.0 International License.

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