Are you ready to build an Ultron of your very own? Well, just the mask. We saw how making Ultron went for Tony Stark in Avengers: Age of Ultron. Michael Ruddy of Hero Complex Props, Jacob Morin, and Sean Shaw of Shawshank Cosplay Props teamed up to create an Ultron mask using 3D printing. Morin designed the helmet and sent the file to Ruddy, (his company’s mission is to help cosplayers impove their overall look by supplying 3D printing) and he printed it using a gMax 1.5 XT 3D printer from gCreate. He split the design into four parts that took a total of 80+ hours to print. Rudder then sent the pieces to Shaw who assembled them (he glued the pieces together with Bondo and then sanded and polished them) and then used a silicone mold and cast the finished helmet. The helmet was then painted and brought to life with glowing red LED eyes.
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