I recently finished my first cosplay ever, Samus Aran. You can check out my build progress in my thread over on
The RPF!
TL;DR
- The helmet, shoulders, chest, arm cannon, elbows, and forearm are all 3D printed.
- The upper arms, thighs, shoe tongues, and shins are craft foam covered in Worbla.
- The shoes and lower torso are just craft foam.
- The glove is just Worbla.
- I 3D modeled the prints all on my own.
- It took me over 2 years to complete.
- It cost approximately $3000, with the 3D prints costing about $1200 (cost of materials only - it would likely cost 3 to 4 times that much if done via a 3D printing company).
- My friend Matt Serle ran the prints for me on his
Zcorp 450 3D printer, which prints by laying down a thin layer of plaster powder and injecting a liquid binder.
- The printer bed is 8"x10"x8" so most of the armor had to be printed in multiple pieces and then glued together.