Suit up with this list of awesome 3D printed Iron Man suits! You're sure to become the next genius, billionaire, playboy philanthropist.
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:
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!
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.
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.
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.
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.
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.
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.
(Lead image source: James Bruton via YouTube)
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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