IRON MAN MARK 6
BUILD PROCESS PHOTO SLIDESHOW
Initial model render - base model by DO3D. Custom sculpted alternate chest plate by me. Base helmet file by VEK3D on instagram, battle damage sculpt faceplate by me.
Render of base DO3D model as previously mentioned.
Custom back internals modeled by me to fill the gap created by the cut out back flaps.
Render of previously mentioned back flaps in open position to demonstrate alignment, movement and fitment of pieces together.
When fabricating the suit, I started with the legs first. This was to ensure that the legs were proportioned correctly and to prioritize mobility. Along with the cod (waist) piece, this was the first test fit of all pieces of the lower body sans the calf flap.
A metal hinge was cut and assembled. Chicago screws were used to joint the pieces on the leg, allowing for full 360 rotation and the ability to disassemble the legs if needed. A third double joint piece was later added to allow for more flex in the knee area, as well as assemble the knees.
The arc reactor was resin printed and fit with a custom modeled threaded casing that allowed me to screw it into the chest cavity. This way, you could remove it for show, and also for maintenance purposes. Neopixel LED rings were layered to create the correct amount of light.
This is the amount of brightness and color achieved after layering the inside with frosted acrylic and a baking sheet for diffusion.
The helmet was completed shortly before the legs. It was sanded, primed with filler primer, and a base coat of black was applied. Rustoleum gold finish was applied to all parts, then metalcast red paint over the red portions. Before painting on the gold, battle damaged parts were taped off so that I could airbrush it accurately after the main paint job was applied.
An image of the level of shine that was achieved on the helmet.
After getting about 80% of the pieces printed, a full test fit was done to ensure that everything was proportional and fit correctly.
Each ab was separated in order to allow myself more mobility in the suit. I created 3D printed mounts for a hooked metal rod, so that all abs stayed together while flexing.
Here was the final ab setup. Flaps were plastic welded in to hide the gaps between abs when flexed, as well as added elastic on the edges for backup.
First full test fit of the arm. This was fit with a rotating wrist joint made with steel ball bearings, and a double hinged elbow using magnets and 3d printed rods. Slots were cut out of the forearm for missiles.
an image of the full arm laid out, sans forearm missile launchers.
Testing placement of the removable chest panel and how it would fit together, as well as the moving trap missiles.
One of the first prototypes of the trap missile pod mechanisms using 3D printed tracks and gears.
Many iterations of the trap missile pod mechanism.
Forearm missiles finally 3d printed to the exact size of the slots cut, as well as oriented to line up with the servo holders inside.
Inner detail panels for the calves found on the RPF and modified to fit into the legs of the suit, to fill gaps when opening.
Paint finish on the battle damaged chest panel.
A photo of the motorization process, best if compared to the original render. Custom mechanisms were created to allow for full movement of the flaps.
A closer photo of one of the custom mechanisms designed for the wing flaps.
Paint finish on the suit before the battle damage was applied.
A photo after the battle damage was applied using airbrush and rub n buff.
Full light test on the torso, screen accurate colors and placement. Blinking LEDs were added to the chest panel to simulate depth and add realism.
The servo mounts for the forearms. Each arm was fitted with 7 servos.
A close up on the battle damaged finish on the thigh.
