The pilots of the Interstellar Manufacturing Corporation (IMC) in Titanfall operate Titans. It’s a little like pilots who operate Jaegers in Pacific Rim. Cosplayer Craft Access spent at least a month building a replica of the pilot costume from foam and acrylics:
Main construction is mix of 3,4,5mm foams and some details are using 3,4mm clear acrylic. the visor is cut from a 3mm clear acrylic and engraved with a laser cutter. Side pouch on the right is the battery pack. consist of 18pcs AA batteries for easy access and to replace in case of battery ran out. Almost all the pieces are lasercut. Base file are from pepakura exported to Adobe Illustrator where all the extra detail layers and engrave details comes in.
He documented the build with dozens of photos on Facebook, and you can watch the suit come together all the way from sketches to cutting foam to adding acrylic detailing. He used three blue LEDs to light the acrylic visor and as you can see in the top photo, there are several electronic touches.
See more WIP pictures at Facebook.