IRONMAN MK 43 whole Suit 3d printed [WIP]

Venom1989

Active Member
Hello everyone
I am a big fan of Iron Man and I always wanted to build a complete Suit for myself. I had quite some experience in building cosplay props and costumes with Eva Foam, but after 3d printing became affordable in the recent years I decided to tackle this project with new enthusiasm and this new miraculous technology.
I bought a used Elegoo Neptune 3 plus for 250€ in December 2023. naturally, like everyone who gets his fingers on a new toy i was quite excited, but had to realize that I need to learn a bunch of new things before I can finally build my dream project. After a steep and intense learning curve I was finally able to print some decent objects with a nice quality. Of course there were some setbacks, like some loose belts, lack of experience and problems with the right size calculation of some parts which led to reprint the whole back and front of the chest, but all in all it went well. And hey - That’s the funpart - right? Learn from your mistakes and take the chance to improve yourself - the journey is the goal.
Damn - what a long Journey. Endless hours of sanding - priming - sanding again - priming again, over and over.
I know this is my very first 3d costume and a lot of things aren’t super smooth and clean - but hey, just give it a good washing and a used / damaged look and no one will see the imperfections (unless you get veeery close)
I want to share my experiences and work with you guys. I hope to improve myself and my work and would like to hear what other (3D print) cosplayers could tell me to progress more.

So I started with the most important part: the Faceplate & Helmet

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Even If the N3+ is a very big sized printer i decided to split the helmet (newbie’s choice)

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I was very impressed of what this machine is capable of - if tuned properly (many hours of YouTube research + trail & error)

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Next parts where the hands +
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Attaching both sides of the gloves with magnets & hot glue to open/close them

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The obvious must-have picture while building a costume

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The gloves & wrist shield now with some damage-look

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Added the LED eyes (bought on Amazon for ~ 30€) and of course: used the washing and damage look to hide some minor imperfections

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Next parts where the shoulder, the bizeps and the forearm. After some trouble with a loose belt and some very frustrating troubleshooting with a damaged bearing i was able to print, prime, sand and paint this in 2 weeks
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Slowly it’s starting to look like my dream-project. At this point I’m back into cosplay making for 10 weeks (after a 4 year break)

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The massive backplate (which I had to split of obvious reasons into 4 parts) - sanded, primed & painted with the basic color.

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Another load of work for masking the different parts
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Clean - good.

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Dirty & rough: better

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The very first time the suit came from a puzzle of different shaped objects that made my living room a mess to something you could say is at least 1/3 Ironman
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Some details added: the arc reactor. I used a simple LED tent light I literally glued into the front plate
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Gluing different parts together with elastic straps and bucklelets (Bizeps /ellbow / forearm / handcover)
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I made a new stand for the suit
At this point it’s around may/june
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The backside of the suit.
New part: the belt , butt & cod cover are attached
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Time to start with the legs
I separated the shins for better comfort while suiting up

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Next update will be in a separate post
 

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The journey continues

My building schedule:

- Printing
- sanding with a powertool (60 grid)
- spray putty (1st run)
- sanding with 120 grid
- spray putty (2nd run)
- sanding with 180 grid
- spray filler
- sanding with 600 wet paper
- color spray (2 coats)
- taping/masking
- second color (silver/gold)
- clear coat 2x

The backside of the lower leg

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Front of the lower leg - finished till fillerprimer, the backside ready for weathering, the boots nearly raw print

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The backside of the lower leg
Later both side were connected via elastic straps which keeps them together but gives me enough space to fit my leg trough it.

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Some parts while getting ready to attach them. I build a harness to support the arms and the upper legs
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Added the neck. I separated the neck, one side is connected via flexible straps, the other side is Held together with 4 magnets
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The left lower leg in its final form
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My latest print - and one of the biggest. The thigh. Printed in one single run - around 42h with 0.3 layer high

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The thigh is already sanded, primed and painted. It needs to get the same used look as well. After this my next step is to connect 1 leg completely and then repeat the same technique with the other leg.

Oh boy - what a massive amount of working, but I think it’s still worth the effort.
 
Looks great!! What colors are you using?
The Mark 43 has always been a favorite.

I'm looking forward to more posts
THX mate

The MK43 is my favorite since the avengers movie came out. Back then I tried the helmet with EVA FOAM

Left 2016 - right 2014
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COLORS: Duplicolor all the way

- DUPLI-COLOR 385858 CAR'S Rallye-Clearcoat

- DUPLI-COLOR 385919 CAR'S Alu Silver

- DUPLI-COLOR 706868 CAR'S red metallic

- DUPLI-COLOR 467400 METAL ANTIQUE Gold

I am very happy with colorscheme - after some research these colors seems to match the original colors the most.
 
I have a question, where did you get your files? I am also trying to do a similar thing (3D printed MK 42) and have an Elegoo Neptune 3 Max, and I also want to know roughly how long it took to print, along with roughly how many kilos of filament you used. Thanks.
 
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