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Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep
3D Printing!

But before I get into that:

I love cosplaying. It's so loving nerdy. A nerdy hobby that is usually a part of a larger nerd hobby. A nerdy Russian doll situation.

I usually do super lazy poo poo. For a few years I've been using a skull mask and some army/tactical poo poo I have and using any excuse to dress up as Ghost from Modern Warfare 2. But it's getting so old and lame. This year, at FanExpo, the level of skill and care being displayed by the costuming community was so intense. I decided it's time to retire Ghost and try to keep up with the jonses and make something really killer.

My brother built his own 3D printer. He's a tech wizard, super smart. But not creative. He had no idea what to print with the drat thing. So we did a 3D scan of my head, and found a nice T-800 skull 3D file online. We used my head as a negative and created a mask that was form fitted to my face and head. So he printed the jaw for me. At this point his printer needed some repairs and he just couldn't be bothered. He was bored with the printer since he learned all he could from it. Now he's on to electric cars.

So my friend and fellow goon/super nerd Linux Assassin got his own printer. This one is pre assembled and tested. But being an off the shelf/out of box printer, it doesn't have the same precision as the home build. The next chunk of the mask didn't have the same fine texture.

I was hoping to have a useable mask by halloween, but the second printer didn't arrive on time. So I have 2/3rds of the mask. At least now I can take my time over the winter and spring and have a nice finished product.



I got impatient and decided to paint it anyway, just to see how it was coming along. The lower jaw is almost done. The upper jaw/cheek piece will need lots of sanding and drilling. I think the upper teeth are a write off and I'll probably get some novelty costume/toy teeth and glue them on.



I feel strongly that the potential for 3D printing being applied to cosplaying is unlimited. But I do need to impart that your printer will not poo poo out perfect, wearable masks/props. Just like other propmaking techniques like vacu-forming, this is actually quite labor intensive.

3D file shaping 8+ hours (3D scan took very little time, and the terminator skull was a pre-existing shape created by an artist and posted online for use with 3D printers)
Printing time on the upper jaw alone 22 hours
sanding, filing and painting 6+ hours (not complete)

ultimately I want a full skull, covered in a tattered latex human face, with tufts of burt hair stuck it. Fake blood and light up LEDs eyes.

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Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep

Bag of Hamsters posted:


This fucker has been an exercise in frustration, since I've never made rigid armour before, not to mention some of these are her body parts and don't follow laws of anything. The breastplate went through five versions, and ended up being foamies sandwiched between two sheets of Wonderflex:



Five darts to get the right curves. Dents and seams were filled in with Bondo 907, then sanded. Battle damage was added with a hot knife, and after a lot of filler primer, the paint job is a bunch of different Rustoleum Hammered colours, then light passes of chrome paint and gold [to simulate sand damage]. Weathering was a combo of green pearl, black pearl, and matte black acrylics, dabbed on and then patted with a make-up sponge.

I really need to see this broken down into more steps. How do you shape those materials? How did you get the weathered metal look? Your work is incredible and literally keeping me awake at night.

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep

fallin1 posted:

My camera was pointing upwards at me from one for the counter tops, probably why it looks like that.

Let me know if there's anything else you need for a Leon costume, I have piles of useless tactical poo poo laying around

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep

Estraven posted:

That paint looks so pretty! I'm excited to see your whole costume.

I could use some advice. I'm cosplaying as the protagonist of Hotline Miami (Jacket) at PAX East this month. I want to put a lot of fake blood on my clothes/mask but I'm not sure how to do it. Should I splatter fabric paint on my outfit or will actual fake blood work? I'd like everything to look suitably creepy but I obviously don't want to actually drip anywhere and leave a mess at the convention! Any suggestions on what I can use would be super helpful.

See you there!

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep
Helping my brother out with a crazy modern Captain America costume he wants to do.



Voodoo tactical gloves combined with martha stewart paint.

I have started rough work on a Beta Ray Bill get up.

For those of you attending PAX East I'll be dressed as Ghost (see AV pic). Please say hi

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep
I've kinda put the Terminator project on hold for now.

My brother and I are on a huge marvel kick so I decided I wanted to do a super hero. But a less common one. Beta Ray Bill checks all the boxes: obscure but some people should still recognize him, looks badass, hides my face, I should be the only one at even a large convention dressed as him. And if I gently caress up the mask really bad I'll have 90% of a good Thor costume.

Preliminary rough sketch, using duct and foil tape to hash out how this will sit on my face.



The few attempts I've seen at this character result in huge, oversize mascot heads. I really want to avoid that. I was watching Face Off (awesome show if you want to learn about make up effects with a small side of costuming and character design) and they did an episode where the contestants had to do werewolves. One of the judges mentioned that you can't add a huge snout to a human skull, it never looks right. I kept that in mind and used a 'less is more' approach. I am using wonderflex for the mask and likely the armor later on.

Here is what I have so far.


Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep

Admiral Goodenough posted:

Wow, that looks great so far! How easy is wonderflex to work with?

Super easy. I find it's best to work with little patches at a time. Firing a heat gun a wide surface area can lead to buckling so when I do large armor pieces I'll keep my distance and be more patient.

When it heats up it's like duct tape. You can roll it into shapes, it sticks to itself. It's forgiving too, if you gently caress something up you can heat it back up, it loosens and you can reshape or remove parts if you have to.

Cuts easily with good scissors.

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep

ExplodingSquidx2 posted:

So I'll be heading to my first SupaNova this year, Australia's mini comicon eqsue thing.

Anyhow I plan on going as Deadpool (like everyone else) but with a small twist.

I'm getting a special effects makeup artist to make my head all gross like his, so I can take my mask off.

I'll post pictures as it happens, but I need help in his gear. What the hell do you call the belt and sword holders he uses? I've tried searching ebay but I'm stumped on what to search for.

Technical term is scabbards. Depending on your cons weapons policies you may be allowed to walk around with china town cheap rear end swords and airsoft guns.

For the gear, the military term is webbing with ammo pouches, more modern is called a battle belt with H Harness.

Nobody does cancerface Deadpool so tip of that hat to you!

edit: internet says metal swords and airsoft is a no go. You might be best off just fabricating scabbards with dummy sword handles sticking out.

Flanker fucked around with this message at 20:02 on Apr 8, 2013

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep
Made some progress on my Beta Ray Bill mask today



I think I'm going to reduce the jaw to just the 'bone'.

Ignore the derpy teeth they are temporary.

I'm either going to block out the eyes with reflective lenses or get those white out blind dude contact lenses.

Next step will coating the mask in caulking or something to muffle the ridges of the wonderflex.

Any suggestions?

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep

Fatkraken posted:

What's your plan for finishing it? Just paint whatever you end up covering it with? fabric covering? Some kind of fake skin?

Yeah paint, but tell me about fake skin I'm all ears

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep
Beta Ray Bill mask is coming along.

I got plastic horse teeth from eBay!

http://i.imgur.com/uG9Eoue.jpg

http://i.imgur.com/RpCC4sU.jpg

http://i.imgur.com/bPJvZ7M.jpg

http://i.imgur.com/mYtvuRb.jpg

I think I'm going to add more to the cheekbones. After that and a couple finishing touches I'm going to gesso the poo poo out if it

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep

Jet Ready Go posted:

What material is that? Your mask looks plastic.

It's Wonderflex. When you heat it up, it goes limp and becomes sticky, like duct tape. You can then shape it and when it cools it's very rigid.

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep

a cock shaped fruit posted:

So 20 minutes later I returned from the 24 hour store with yoga mats and a roll of duct tape...

I wonder what percentage of yoga mats are being purchased for non yoga activities. My brother bought a yoga mat from wal mart at some strange hour for his Avengers Cap costume.

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep
Hello people way more talented than me!

I am working on a costume for FanExpo Toronto coming in August 2013. I started this back in march but finally felt like doing a build thread about it.

Character is Beta Ray Bill from Marvel Comics.
http://marvel.wikia.com/Beta_Ray_Bill_(Earth-616)
You might notice when you scroll through images of this character that his appearance is somewhat inconsistent from artist to artist. I will be no exception. I will be taking creative licenses in areas that I find difficult to copy or build, or concepts that just would not look good in person.

I got two sheets of wonderflex for about $100 because I shipped it to a US address and picked it up in person.

I'm using the wonderflex for the mask and most of the armor and such. That poo poo is a miracle, heat it up with a heat gun and it wilts into duct tape, shape it, it cools and your're good to go. Very forgiving and easy to work with. Larger areas are tricky since uneven heating will lead to buckling and warping. Smaller pieces can liquify and become fragile, to well bonded to be corrected later.

Here's where I started with the mask.

http://i.imgur.com/ZDLHlmdh.jpg

Here the scalp is filled in with scrap pieces and I'm holding the lower jaw in the shot. I initially wanted an articulate jaw that moved with me when I spoke, but I have since abandoned this concept for the sake of simplicity.

http://i.imgur.com/t4xr53Ah.jpg

Those teeth were obviously place holders, I found plastic horse teeth on EBay!

http://i.imgur.com/DvhBAHVh.jpg

More material added to cheek bones, another layer over the upper jaw to bed in the teeth.

http://i.imgur.com/eC29uFMh.jpg

I used some sculpting paste to try to dull the straight edges from all the interconnected scraps I used. (When using wonderflex, definitely keep a bag of all your scrap trimmings. This stuff doesnt grow on trees, as you'll see later, entire pieces were fabricated from my trimmings).

http://i.imgur.com/eYZPFfuh.jpg

http://i.imgur.com/dzTRv7ah.jpg

Gauntlets!

Here's where you're going to see that creative departure kick in. Also notice the bowl of scrap trimming in the background. Anyway I am going with the three fingered approach because it further re inforces that Bill is not human, and its fun as hell.
http://imgur.com/a/6iHGg

All of these armor pieces were cut from the scraps I kept from working on other pieces. Also you can see I've written all over them, keeping track of which finger and segment this are. Since it's all going to be painted I figure it doesnt matter.

http://i.imgur.com/VCSXQXUh.jpg

Paint! I'm using rattle can stuff from home depot and canadian tire. Wonderflex doesn't seem to care what paint I hit it with, it wears it like a champ. In terms of artistic license, I am replacing white with silver and yellow with gold for visual effect.

http://i.imgur.com/mITCIJlh.jpg

http://i.imgur.com/2fKmBHlh.jpg

I made some bracers that attached seperately but give the illusion of a gauntlet look. This was before painting.

http://i.imgur.com/6qWLO2lh.jpg

Catching up to the present, this is late June at a friends place starting to work on a helmet. At this stage, I was being even more cautious with material usage, finally starting to draw objects on paper and approaching the builds with a more thought out plan. I should have done this from the start.

http://i.imgur.com/N1TYo8Bh.jpg

http://i.imgur.com/Bc5xNhRh.jpg

http://i.imgur.com/z5KRbYBh.jpg

Here's the complete, unpainted helmet with the mask so far. I found a colour I like for his skin, but I don't like the texture and will probably do another layer of paste to get it nice and smooth.

http://i.imgur.com/IFmnt21h.jpg

Crappy 'so far' pic

http://i.imgur.com/jTwMFbvh.jpg

I have since lost ten pounds since this pic was taken, since nobody wants to see Frito Lay Bill. I'm thrilled with how the gauntlets look. The helmet looks ok too. I am playing with a vinyl vest/tunic thing but its coming a huge time vampire and I might dump it in favour of a black spandex compression shirt set up.

Up next: the unending trainwreck of fabricating Stormbreaker, Leg armor, belt and buckle. Still building: Thighs, chest orb things, shoulders and cape.

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep
I got interviewed about costuming, I made a crack about prom dresses and of course thats the line the reporter uses.

http://www.cbc.ca/hamilton/news/story/2013/08/21/hamilton-fan-expo-cosplay.html

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep

FloYo posted:

This is my Psylocke Marvel Now cosplay for this year's Fan Expo:




I'm so mad I entered the masquerade instead of just hanging out and doing the Marvel photo shoot.
Don't enter the Fanexpo masquerade unless you're a dress maker and also want to give up most of your Saturday in a green room.

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep

FloYo posted:

Aaaww man. Who did you dress up as?

Beta Ray Bill



http://i.imgur.com/NkE2iEyl.jpg

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep

PezMaster posted:

I've seen pictures of you floating around tumblr/twitter! I remembered you were working on the mask and had some pictures up in this thread, but I don't remember seeing everything come together. It looks really great! You've got to post some close up shots of that mask, though. From what I remember, it was pretty badass. And had terrifying horse teeth.

Where did you see pics?

I got Stormbreaker (the hammer/axe thing) signed by Walt Simonson, who created the character, he was super thrilled, as were some of the other staff from Marvel. Just makes me want to go more hardcore next year.



Anyway I took these for you, with bonus Frog of Thunder action




Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep

fallin1 posted:

^Holy crap this puts my wip shot to shame.

Scrapped my original design on my Corvo mask and I think I works for the better.



No thats the finished/mask and helmet I wore to the con :/

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep

fallin1 posted:

I realized, even when mine is fully done I doubt it will anywhere near as good as what you made.

I am overall un satisfied with it. I think your split open skull mask is way cooler.

For all the time I spent making mine, I should have gone all in and made a hard core foam latex mask or something cool like that. Probably for next year, the character was a huge hit so I'm going to build him all over again.

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep

fallin1 posted:

Oh hey foam latex is what that is. Was kind of a pain to cut too.

Is it flexible?

Flanker
Sep 10, 2002

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After a good night's sleep

Fatkraken posted:



Most commercially available masks aren't made from foam latex, they'd use various synthetic foams, plastics and rubbers like expanding polyurethane or vinyl or whatever. Ones made by small studios and hobbyists are most likely to be something like flexible expanding polyurethane foam since that can be bought as kits from various suppliers and don't require an oven to cure.

I want to know more. For a four day con, I'll take toughness over other considerations.

Tell me about silicone masks

Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep

Fatkraken posted:




All the above methods require MOLDMAKING, where you make an original in some sort of clay or wax then make a mold and use that to reproduce that sculpture in a different material. In general, a rigid piece requires a flexible mold, and a flexible piece a rigid mold. A simple slush-cast latex piece will often only need a single one part hard mold which can be made from an inexpensive material like plaster. On the other hand, even a relatively simple animatronic head might need ten+ molds all in plus their associated multi-part rigid mother molds, for the skin, the back side of the skin, the rigid underskull, the teeth, ears, supports for the servos and so on. I am planning on making an animatronic head and budgeting $500+ JUST for materials. A simple slush-cast latex head with no support or a papier mache or wonderflex underskull could be done for well under 50 bucks (though the initial outlay would be more, a lot of this poo poo is cheaper to buy in bulk)

tell me more

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Flanker
Sep 10, 2002

OPERATORS GONNA OPERATE
After a good night's sleep
Last minute, but anyone with a good super hero costume near Toronto, there's a charity event in Bowmanville on Saturday looking for help.

Pm me for details

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