Nov.15, 2013

In 2011, Ryan Brooks's passion for all-things Iron Man inspired him to teach himself programming, electronics, 3D modelling and mechanical design, with the intent of bringing the onscreen armor to life. His first attempt was the briefcase suit from Iron Man 2, which is able to transform from a slightly large briefcase into the fully detailed and fully functional suit of armour. The Discovery Channel's Daily Planet featured him, and he also made the front page of the Kitchener-Waterloo Record in 2011, and won "Best in Show" with the debut of this costume at ComicCon 2011 in Toronto.

Inspired by the first Iron Man movie, this year Ryan wanted to make his own Mark III Iron Man suit. He started researching online and found some others that had made different kinds of Iron Man costumes. But most of them are just costume. Ryan wants to make something functional, authentic, and with light on.

He started with making MkIII Iron Man Helmet. Using a Stratasys Fortus M360 3D printer from a 3D print lab at the local university, Ryan 3D printed all the parts of the helmet in plastics. Ryan introduced his first 3D printed Mark III Iron Man helmet in July. It took him about 100 hours to develop and fine-tune, but it incorporates all of the functionality he sought to include. In his first video below Ryan demonstrated the mechanism. One of the key features is the ability of the base of the helmet to "cascade" up inside the helmet, allowing the wearer to place the helmet on their head with ease.

In a second video in October, Ryan showed off a complete version of the Mark III Iron Man suit which is polished, fully painted and lighted. This version incorporates his Servo Mechanism 2.0 which is based on an Arduino Pro Mini with an Adafruit accelerometer.

The servo mechanism is triggered by the accelerometer that detects sudden movements forwards or backwards, creating a hands-free method of controlling the opening and closing of the faceplate.

The red paint was done in three layers: a base layer of Duplicolor Platinum, three layers of Metalcast Red, followed by three layers of Krylon Satin Clearcoat. The gold paint is a Krylon Gold followed by the satin clearcoat.

Watch the video below:

If you would like to make your own Iron Man helmet, you might want to get Ryan's servo mechanism which you can find here. Currently Ryan has started making models for the arms and legs. Maybe in the near future Ryan will be able to show us a complete suit incorporating all the movements. If you're interested in following what he does, check out his website here.


Posted in 3D Printing Applications



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Lachie wrote at 9/5/2017 8:19:37 AM:

I wish he included the STL files that helmet is great

Todd - IronManTF wrote at 6/20/2016 5:49:15 PM:

Wow, great work! Do you have the .stl files to print for this helmet? I will be bookmarking your website and I can already tell you that we will be doing some future business. Again, great job!

alvaro wrote at 11/18/2013 1:15:25 PM:

The next step of mr Ryan is to combine it with the google glass technology. Congratulations mr .Ryan "Stark"!

KnightFire wrote at 11/17/2013 3:13:30 AM:

It's just a tease, he doesn't list any STL helmet files.

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