3d Printed Iron Man Suit | My Custom 3d Printed Iron Man Suit (an Overview)

Emily The Engineer

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My Custom 3d Printed Iron Man Suit (an Overview)


Hello, welcome to the video where I show you pretty much. Everything I’ve done with the Iron Man suit. I would say it’s done. I have a couple of things. I want to add here and there, like maybe mobility wise or cool factor wise, right. Maybe I wanted to shoot something. I don’t know, but for the most part, it’s done it’s wearable, And I wanted to show it off and I’m gonna go ahead and put it on because I know if I don’t, everyone’s just going to skip to the part where I put it on. So gonna go ahead and do that now. It’s in this box. Yeah, it all fits in a single box. That one does too. So you know, pretty nice. Uh, this is the helmet. It’s wrapped in a Minecraft blanket. But, you know, it does its job. We gonna set this fella right here. And I guess I’m gonna put it on for you guys. This is a fun process. Now disclaimer. Um, last time I used this and was wearing it. I filmed a tick tock where I tackled. My brother probably wasn’t the best thing to do in it. A buckle came off of the chest, which is very expected, but the important part about it is nothing broke and by nothing. I mean, like none of the serious parts, right, but maybe the tackling was worth it. We got a little bit of battle damage here and there. It just makes it more authentic. [MUSIC] [Music] all right, so it’s on, I’m able to actually put it on all by myself, which is a huge improvement. From that guy, right. You suck, okay. You really do so again? It’s a little clunky. You can kind of hear the plastic hitting each other. I still have some things to pad, but just kind of wanted to be able to show you guys what it did. So first of all, we’ve got the back flaps open. I’ve stuck the button, It’s in my glove right here. So whenever I press that, these guys open up, here’s a closer look at the back. There’s some Leds under there, too. That light up whenever they come up and again, I literally just have a button in my thumb, and I’m able to press that second of all. I’ve got the arm missile. Um, this guy is just activated with a pressure. Switch underneath my wrist So every time I pull my wrist down, It opens up like that finally. The most popular part is the helmet it opens with a button in the chin. So that way I’m able to use the helmet separately from the suit and it’s not wired into any other parts, too. In this guy. All the wires from the helmet went down to the chest, which means they had to run down the neck piece, which was the most uncomfortable experience of my life, but yes. This is the suit! Um, I’ve still got some little bits. I want to fill in with, like some foam or something. Or tpu. You can see these little open gaps. I will say it is pretty mobile. Sitting down is a little harder. I have to have help with that stairs a lot easier. In this guy, how’s it feel to be replaced but yes. This is the suit, this is it. Um, I do plan on wearing it out in public. I think that would be really fun, but I did want to give you guys some more insight as to how things work, um, a little bit more of the details as to how I made it and all the different parts. So if you’re interested in that here, you go, okay, so in explaining a lot of how this works. I figured we work from bottom to top first of all. These are the boots I printed these in like, 30 infill. They’re very heavy. Um, I put like foam padding along the inside and some on the bottom. So I actually just wear my socks. Slip my feet right into the shoe. Um, it’s hinged in the middle, so I can kind of walk a little bit and I did buy some rubber padding. I want to put along the bottom just so I don’t slide around. If I’m walking on a hard surface, another point of interest that people have been asking about are the knees. This is the thighs, the shin. They’re both in two separate pieces, and I had to have them in two separate pieces, because unfortunately, the way that the thigh is made, I literally am unable to stick my foot through this way because this kneecap kind of gets in the way, so I have to awkwardly turn it this way, and then once my foots through, turn it the other way, so it was impossible to leave the two like completely attached. I don’t know if it’ll focus. But this is a hinge from a knee brace. I just ordered off of Amazon because one of my goals was to have the kneecap centered. Whenever you bend your knee because on that guy, right, I had to attach the kneecap to the shin. So that every time you bent your knee. There was like this huge gap. There and I didn’t like that so in order to keep the kneecap in the middle. This is the kneecap. I designed this brace for it that fit around the hinges, and I put magnets on either side of them right there and there. If you can see, I epoxied those in and that way after I put the leg on, I can clip this in. It stays like that. And then whenever I bend it, it goes along with the kneecap and I push it back up. It goes back with it, and then as far as how it connects to the shin on the inside of the shin, so I plastic welded two little clips there and each of the hinges slide through both of these slots. So when I put the shin on, I just line up the hinges with each of the slots, it’s hard to do with one hand, and it goes in like that, but obviously, if I were to like, stomp on the ground sometimes, um, this can slide further into the shin than it’s supposed to go and that can pop the kneecap off, so I would like to go back and redesign that at some point, and then additionally, for anyone wondering, you can see all the wear and tear that’s been on the bottom of these shins after I’ve worn them for so much, Um, but this portion is made out of tpu, which is a flexible filament. Uh, so that way I’m able to like, bend my foot a lot better. These are in multiple parts, so that already helps, but like these pieces actually bend really well and to paint those you have to use acrylic paint. Because if you use any other type of automotive paint, it’s just going to crack also. Can we just appreciate how well I was able to color match this, okay. This and this they weren’t from the same spray can or anything like I literally had to match. This color with acrylic paints to this. Okay, just saying moving on up. I’ve got them like all sprawled out on the floor. Right now! The AB pieces. All of this! This portion right here is made out of pla, so this is tough like rigid filament. Um, but I did have breaks in it because obviously one of the big goals with this was mobility. So I put a cut here a cut here. Um, but then I just backed it with foam so that you know they’re rigid pieces, but I can still move back and forth. You can see that piece of foam there, but everything is still pretty flexible. These pods are printed out of PLA and just kind of attached with a flap of foam. But then this guy up here. This is tpu. How flexible the AB piece has been has definitely been like the biggest help in mobility for sure, just being able to move side to side without like being constricted. That guy back there is just like a plate on my stomach of rigid material. You can’t bend this way this way that way. It’s terrible, but very happy with this again. Can we appreciate the color match? Yes, oh, yes, the other portion of that abs, which is pretty important. Um, are these so the way it connects? Is it connects up to the chest piece right here. Um, the sides of that back of the AB piece right here and the bottom of it all with buckles pretty easy. Um, and then we’ve got springs going down the back of this AB plate. The do 3d files that I used came with them like flat as a slab. Right like that guy, but I decided to go in and slice these into individual AB pieces, and then I don’t think you’re going to be able to see, but I did 3d print individual hooks for the spring to like spin into, and I place them along each plate at the top and the bottom, and it holds it together very well, if I bend forward, it obviously does this number here but again. This was probably one of the biggest contributors, uh, to being able to move a lot next part. You guys have seen the chest. Um, anyway. This is the back of it. It’s just got a crap ton of buckles. Uh, these up here are to connect the back brace. These are on the sides. And then these are to connect the AB plate that I just showed you. You can see my wonderful, ugly soldering job and just the tiny little battery pack right there. Flip the switch arc reactor Turns on Ive. Got this whole thing padded as well. Just because you don’t want to have any like rubbing. Obviously, the abs would be super scratched up if they were to collapse into the chest and not have this padding again. Something that I did with the back and the chest Only is I fiberglassed them? Another reason, why? I think it did not implode on itself. When I tackled my brother the other day, my fiberglassing isn’t perfect, but I’m getting better. This is about two layers of cloth and resin and then a final like really thick layer of resin on top. I’ve found that’s helped a ton with just making the job. Look a lot smoother, but yes, that’s the chest, one of my favorite parts here, probably because I think I modeled this myself, so I’m gonna be pretty hyped about it. This is the back brace. I designed. I designed it to like, fit me pretty snugly. And thankfully it does that. This is the outer back. Which is what everyone else sees, right, but I designed this, so it has flaps with magnets place magnets on the inside of this guy as well and I can actually hook it over on top of these magnets like that, and it clips down into place pretty well, too, like if I turn it upside down. I’m gonna be careful here, but I am pretty proud of this. It stays pretty well like I’m not holding on to it or anything. I’m just holding on to the brace. So the idea is that the outer shell just has these flaps that move up and down freely. No motors on it. Nothing, but underneath is where you have. The motors attached to the back flaps and just some like underneath parts to make it look cool. So these are two servo motors that open the flaps up and down. Basically, I just designed and 3d printed these real quick. Um, took the servo arm, just welded it in there and then just had like a little push arm just to be able to push the flaps up and down, and that’s literally all you. Do you take them? You attach them to the servo. You attach them in the down position as well, so I’m going to hit a button That’s routed down to my glove and these guys pop open. I don’t know if you can see it with the light, but I also put some colored Leds in there too. Just to kind of simulate rockets. The eventual goal is to actually have compressed air. Come out of this hole. And that’s what this little round portion is for. It was to hold a can of something. Obviously we haven’t gotten there yet would have to modify it pretty heavily, but that still might be the plan. I have for the most part wired everything separately like the helmet. The arm, the back everything’s separate with a different Arduino nano to me, It makes it simpler and, oh, the arms not working well. It must be the electronics in the arm, right, whereas if I were to wire it all together and plug it all up and something doesn’t work All of a sudden, something else might not work. I don’t know, and then troubleshooting becomes a lot more difficult, But that’s just my train of thought. Maybe it’s lazy. I don’t know, looking more at the front. These are the magnets and this is just where the shoulders sit with buckles. So to show you how? I kind of use this, right, I’m going to take the she’ll place it over the magnets until it kind of clicks like that. And then I press the button and both of them Pop up shoulders are boring. They just kind of clip there and stay. There arm is not so boring. I use Chicago screws for the hinges and the arms and everything. Um, those have worked. Great, I’ve gotten like a huge pack of those off of Amazon for like, ten dollars, so we’ve got the batteries turned on right here, and if you can see this right here, If it’ll focus for the 50th time, this right here is a pressure switch, and every time I click it, which ends up being clicked whenever I pull my wrist down, right. This guy pops up. This guy right here is just a little 3d printed case. I made for four red leds. The wires do be looking kind of nasty. I did design, though. The little mechanism that pops it up wasn’t too difficult. It’s literally just two guys that go. Um, but the servos right there, um, just pulls it up with one single arm and then two in the back, just kind of prop the rest of it up pretty simple Pew Pew. I’ll admit to after I built this. I did not stop wearing this for, like, three days. Just walking around the apartment like an idiot flicking my arm everywhere. Here’s the other arm, it’s boring. I haven’t motorized it yet. Both of them do have a little buckle, though, to hold the little palm plate And by those. I mean, this these sit over the top of the hands. They’re just movie accurate. I guess as if I was going for movie accurate with this right, It’s not even red. This guy buckles into here like so, so it sits like that. It can move around has a hinge and then the glove has a little piece of Velcro on the back that sticks to this as far as the gloves. Go, they’re nothing fancy. Um, pla, it’s a clear PLA piece that I just kind of printed real quick and stuck in there. The paint is peeling up a little bit Now after I’ve used them for so long, but for anyone wondering what I did in between the fingers and I got this from my pal Quiera. I’ll link her in the comments. I actually took a rubber gardening glove. Um, took some puffy paint. Put the little lines for the in-between parts in between the fingers and then spray painted it blue. It is peeling up a good bit now. Just because I’ve like, put it through a lot, but definitely my favorite glove. I’ve made so far, I can do so much more with this one than the ones for that guy. I love how I just keep pointing at it. As like, the bad example of everything like you suck. Everything about you sucks coming up on the last two parts here. This is the neck again. Color matched this with acrylic paints all tpu? It was printed in two parts plastic welded. Uh, the back to the side right here. And then I have magnets inside this piece of foam and magnets on the back of this and it just kind of clips in place. I did go through. Um, and divide the file up so that each piece of the neck was separate Just so I could move around a little bit better. I do hate that sometimes. The gap, like shows through whenever I’m wearing it, But the mobility is worth it. And finally bam! I can’t remember if I showed this before. This is my baby. I almost took wedding pictures with this thing, and then I didn’t. Do you want to say the file for this guy was made by my friend. Conrad, I’ll be linking him in the description as well. So this guy has light up eyes the eyes. If you look closely, don’t know if you’re gonna be able to see, um, but there are dots on an acrylic plate, so that kind of allows the light to hit the dots from the side and then reflect out. But it also means you can still see. You can take these acrylic plates. Heat them up, warp them to fit the helmet or whatever you’re making, and they’re pretty neat, obviously. If you’re in like a super dark room, it’s going to be pretty hard to see, but if you’re like outside or something, it’s perfect. Another goal of mine was to have everything combined into one helmet because this guy again, shame on you, all the wires that control the helmet and allow it to open and close are in the chest, Which means I can’t. Wear the helmet and open and close it unless I’m wearing the entire suit, so I put the button to open and close it in the chin. You can see that guy right there. There’s a pressure switch and I put some foam on top of it too. Because it started to scratch my chin, but I just kind of move my jaw and it closes. This part is separate and then kind of just clips in with magnets, but to me, the coolest part of this helmet for sure is the fact that the chin also moves. So this is what the inside looks like. Um, I kind of had to finagle around with it. I know when my buddy Conrad designed it. He kind of designed it to his own head to the servo sizes that he had so. I kind of had to make it work for me. So this is the inside. Um, if you’re wondering, I did put foam here. Some partially take this foam off, But I’ve got, um, Velcro on each of the servos just to hold this in place, but I pretty much got the Arduino nano, just kind of glued in between the servos with all the wires running to it tried to do a little better with, uh, cable management. And then this is the battery box right there. It’s literally just tape because I’m I’m paranoid. It does clip in and out, but it falling out is my worst nightmare, because obviously it would pull the rest of the wires out too. That’s not good, but that’s the battery box. I can kind of turn it on and turn it off, but it is all contained and very fun to wear so a couple more things about the suit. This is me just kind of responding to the most frequently asked questions. I’ve gotten number one. How comfortable is it compared to the last guy again? You suck id! Honestly, say it’s pretty comfortable. The other one weighed about 20 pounds. This one! I do think still weighs 20 pounds, but the weight is distributed much better. The last one had the weight of the legs, abs and chest and back all of my shoulders. This one literally just has the weight of the back and the chest on my shoulders. The weight of the legs is on the legs way to the abs on the abs. It fits a lot better question two. Where’d you get the files? From what did you use? How did you do it? As far as files for 3d printing goes, the main outer shell of the files are from Do3dcom. However, I will say this specific file was not really wearable. A lot of editing had to go into it. I wasn’t able to fit my leg through the bottom of the thigh piece like it was just impossible. So I had to take a heat gun. Warp it out. I’m pretty sure I edited about every single one of the files, except for like the shoulder piece. As far as mobility goes, I had to slice a good many parts in halves along certain seams just to be able to move, obviously exhibit a the AB piece. All of that was like one solid piece for the back. I had to cut the flaps out of the back too to make the move obviously had to edit the arm, so there’s a lot of things that I had to go through one to edit just to be able to motorize, but that’s expected, right, but two I did have to go through and fix a lot of it, just so it was mobile whether that be on the computer or with a heat gun trying to make it bigger, so it did take a good bit of work. I think this was just like the one file That was not wearable, like, for example, This guy, all these parts right here that I have moving and flexible on the bottom. We’re one thing they were all attached to the shin, which would have been absolutely impossible for me to walk in, so I had to do a good bit of slicing right just to be able to make it mobile, and I’m glad I did so those files do belong to do 3d but I had to modify the heck out of them, but everything modified in things like the arm and the back flaps. Um, I did model. I modeled the kneecap holder as well. The back brace. I modeled myself for that. I used fusion 360 and for most of the mechanical parts. I use solidworks as far as slicing different parts and all those different areas that I had to do to make it mobile. I think I used Netfabb and a combination of just like 3d builder If it was a clean cut. But that is what I used. Question three. What printers did you use? This whole suit was printed on two cr-10s, but if you’re interested in getting started in 3d printing, and you’re like, man, I can’t afford like multiple machines, right, I’ve printed my first suit on one cr-10 and I know someone who printed a whole suit on a single ender three, so no excuses. Question four. How long did it take you? I started this project at the beginning of quarantine, but then obviously went into my last semester of senior year of college. Um, graduated in December, so time was hard to come by so taking that into account. It took me about eight months. Question five. How much did it cost for me? It cost me about 500 bucks. The two most expensive parts of this are plastic things to print out of right. Pla abs. Whatever you choose and automotive paints which you use to make it look pretty. I’d say I easily spent about two hundred dollars in plastic and two hundred dollars in paint. I did obviously I already. Have the printers epoxy things like that, but would say I spent a hundred dollars in other materials like buckles. Arduinos so you can do this for a pretty good price. It does take some time, though, and finally question six. Why is it blue because I could, okay. I like blue. I like the mark. Seven, everyone’s always like. Is it rescue like no? I just like I like blue. So those are some of the most common questions. I get just to go ahead and knock them out, but if you have any more, put them in the comments below. I do want to do a q a on this sort of stuff. Whether it be about the suit itself, 3d printing, Whatever I’ll be picking some questions here and there and doing a Q a on those. But anyway, thank you so much for watching I’m sorry. This video took so long to come out. Um, I do really want to like emphasize. If you want to see more of the suit and some of the shenanigans, I pull in it on tick tock. I do a lot of that stuff. I’m also on Instagram, but if you’re interested, all that stuff should be in the description as we’ll be sure to put your questions in the comments because I do want to be able to answer a lot of them. I appreciate you for watching, and I’ll see you. Whenever the heck I freaking see you. I think it’ll be next week. Hold me accountable! Okay, all right, see you.