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July 17, 2014 AT 2:00 pm

3D Printed Iron Man MkVI Armour Legs from XRobots.co.uk #3DxCosplay #3DThursday #3DPrinting

James Bruton of XRobots.co.uk has been revisiting his Iron Man Cosplay project to rethink the boots and legs now that he has a 3D printer:

…I started by removing the cages from the front of the shins so I can make something more comfortable which also fits more snugly. I’ve used a pair of football shin pads and Velcro straps so I can adjust the fittings and brace the load across the whole shin.

The front and back shells will not attach directly to each other using some 3D printed parts. The hooks have been designed with some length to them so they can slide inwards and avoid the tricky contours of the boot. The fronts are held downwards with a bungee in a hook at the front of the boot, provided the front shells cannot lift, they also cannot pull away from the backs.

After some experimentation, it appears that the best way to mount the thighs is onto straps attached to the torso. I would have preferred to support these from the boots, but it appears that the hinge points in the original Pepakura files are not at the same height, or actually where my knee bends, so this is problematic. I’ve used webbing strapping/buckles to mount them….

I’ve designed and 3D printed flexible knee section in Ninjaflex, using my Lulzbot TAZ printer….

Read more.

XRobots 3D Printed Iron Man Cosplay Flexible Knee Sections Printed in Ninjaflex Rubber YouTube


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