What if John Blake built a suit of Nightwing armor? That thought inspired this costume built by Malaki of Mal’s Fantasy Factory and Bryan Lee. It was also inspired by Christopher Nolan’s The Dark Knight trilogy, specifically The Dark Knight Rises. The costume started with a mannequin built to Bryan’s size. To do that inexpensively, they wrapped Bryan from head to toe in plastic wrap and duct tape. They drew lines on the duct tape to mark various sections and then carefully cut the duct tape off and taped it all back together. The duct tape shell was then filled with expanding foam and ready to serve as a base for all the armor pieces. Malaki used muslin to create the patterns for the bodysuit and paper to make patterns for the armor. He created a sizing chart and used a sixth scale Hot Toys The Dark Knight figure for comparison.
Malaki then started creating the armor from 3/8 inch and 1/8 inch thick foam. As he finished foam pieces, he lightly glued them to the mannequin so the foam would curve and take the right shape. Once pieces were on the mannequin, he covered them in Plasti Dip. The process just for the armor looks quite labor intensive. And then you have to add the bodysuit, the goggles, and light-up weapons into the mix. Whew.
Check out more photos of the build at Facebook.