Ultron doesn’t have any strings on him, and in this case, he doesn’t have any metal either. Yesterday I showed you a 3D printed, plastic version of Ultron’s mask, but Villages’s Hope took a different approach. The Thailand based costume makers worked with Walt Disney Studios to prepare Ultron and Ultron sentry costumes for the Avengers: Age of Ultron premiere in Thailand. The suits look a lot like metal, but they were made from EVA foam, PVC leather, and lit with LEDs. They said they wrapped the foam with PVC leather, and though I can’t imagine the amount of labor that involved, the finished product is effective. They could have followed a process similar to what RuffleButtCosplay used when covering craft foam with metallic spandex to simulate metal armor.

via Fashionably Geek