Becoming the Dark Knight

batman costume 1

If you want to be like Batman, you don’t have to follow Bruce Wayne’s footsteps exactly. No tragic origin story is necessary – you just need to make the costume. Instructables user sellers.nathan made his Dark Knight costume based on the one seen in Batman Begins. He used a black zentai suit as the base and other materials included: 5-6 tiles of EVA foam, Plasti-Dip spray, and plastic resin. He worked with a friend who has Adobe Illustrator skills to create templates that Nathan then cut out of foam (he shares the files over at Instructables).

After the foam armor pieces were cut, smoothed, and painted, Nathan had to figure out a way to attach them to the zentai suit. He tried to use glue, but it didn’t work out. Velcro ended up saving the day, and with the help of his wife, they sewed small pieces of velcro to the suit and glued the opposite side of the velcro to the armor:

This process took many hours. My wife and I were up very late many nights in a row to make sure this was done by Halloween. We finished 2 days before.

The first step is to cut the strips of velcro to sizes that will fit for each piece of armor. I suggest at least 2 pieces for each armor part, sometimes more. Then, sand down the back of the foam where the velcro will be glued. This is really important. I didn’t do that on a few spots and the velcro comes off with minimal effort. You have to sand through the plastic coating. Then wipe it down so you have a clean surface. Next, put glue on the foam and the velcro and let sit for at least 30 sec. to get a little tacky. Then put them together. I left the pieces together for this. Clamp the velcro and the foam. I used cardboard as a buffer to not dent the foam. Let sit the appropriate amount of hours. After this is secure, you are ready for the next step.

I drew chalk onto the back of the velcro and then placed the armor in the correct location while wearing the suit. This will mark the spot the opposing piece of velcro needs to be sewn on. This is also why the adhesive velcro won’t work… it just gums up the sewing machine.

I had to do this step by step, especially with the chest and abs and ribs. I started with the chest and worked down to make sure each piece worked together. The velcro does give a little flexiblity in the placement, but not much. Placement is really important to make this look good. Make sure there is good placement before sewing.

In all, we ended up having somewhere between 80 & 100 individual pieces of velcro sewn to the suit.

batman wip 1

batman wip 2

Read more about the build at Instructables.

Adafruit publishes a wide range of writing and video content, including interviews and reporting on the maker market and the wider technology world. Our standards page is intended as a guide to best practices that Adafruit uses, as well as an outline of the ethical standards Adafruit aspires to. While Adafruit is not an independent journalistic institution, Adafruit strives to be a fair, informative, and positive voice within the community – check it out here:

Join Adafruit on Mastodon

Adafruit is on Mastodon, join in!

Stop breadboarding and soldering – start making immediately! Adafruit’s Circuit Playground is jam-packed with LEDs, sensors, buttons, alligator clip pads and more. Build projects with Circuit Playground in a few minutes with the drag-and-drop MakeCode programming site, learn computer science using the CS Discoveries class on, jump into CircuitPython to learn Python and hardware together, TinyGO, or even use the Arduino IDE. Circuit Playground Express is the newest and best Circuit Playground board, with support for CircuitPython, MakeCode, and Arduino. It has a powerful processor, 10 NeoPixels, mini speaker, InfraRed receive and transmit, two buttons, a switch, 14 alligator clip pads, and lots of sensors: capacitive touch, IR proximity, temperature, light, motion and sound. A whole wide world of electronics and coding is waiting for you, and it fits in the palm of your hand.

Have an amazing project to share? The Electronics Show and Tell is every Wednesday at 7pm ET! To join, head over to YouTube and check out the show’s live chat – we’ll post the link there.

Join us every Wednesday night at 8pm ET for Ask an Engineer!

Join over 36,000+ makers on Adafruit’s Discord channels and be part of the community!

CircuitPython – The easiest way to program microcontrollers –

Maker Business — “Packaging” chips in the US

Wearables — Enclosures help fight body humidity in costumes

Electronics — Transformers: More than meets the eye!

Python for Microcontrollers — Python on Microcontrollers Newsletter: Silicon Labs introduces CircuitPython support, and more! #CircuitPython #Python #micropython @ThePSF @Raspberry_Pi

Adafruit IoT Monthly — Guardian Robot, Weather-wise Umbrella Stand, and more!

Microsoft MakeCode — MakeCode Thank You!

EYE on NPI — Maxim’s Himalaya uSLIC Step-Down Power Module #EyeOnNPI @maximintegrated @digikey

New Products – Adafruit Industries – Makers, hackers, artists, designers and engineers! — #NewProds 7/19/23 Feat. Adafruit Matrix Portal S3 CircuitPython Powered Internet Display!

Get the only spam-free daily newsletter about wearables, running a "maker business", electronic tips and more! Subscribe at !

No Comments

No comments yet.

Sorry, the comment form is closed at this time.