[3D Printing Applications] FDM and SLA Photopolymer 3D Hybrid Printing: Creating the Iron Man Gloves of Your Dreams!

Why is 3D printing now the preferred method for creating cosplay costumes? Many cosplay enthusiasts are exploring the use of 3D printing technology to create cosplay models and costumes that were previously made of plastic and fiberglass. This trend has become popular not only because the materials are the same, but also because of its affordability, time-saving convenience, and many other reasons!

3D printing unlocks the possibilities for rapid prototyping and virtually unlimited modifications. What used to take hours or even days of hands-on work for a manual project, 3D printing allows you to continue creating even while you're working or busy with other things, saving you more than half the time!

As a huge Iron Man fan, Kersey Fabrications was tasked with creating his own complete Iron Man suit based on his favorite classic red and gold Mark 3. This time, he'll be making a replica of Iron Man's glove, complete with a work repellent ( we were all blown away by what we saw!!).

His creative process includes four important steps :

• Choose the correct model • Adjust the size of your cosplay costume
• Prototypes were created using an FDM printer. • The final model was built using resin prints.

Select the correct model

Choosing the perfect model for your 3D printed clothing project involves a lot of discussion. It could be the shape and style you like, the features you want to achieve, or a model that only you can use. For Kersey's Iron Man glove project, choosing the right model includes finding the correct hand segmentation, considering the installation of the repellent, how to wear it, and how it fits him.

He mentioned that the earliest armor models were usually made up of a single hand, which needed to be cut or split in half. Later, Walsh3D models appeared, offering multiple assembly methods, allowing for almost any combination, and you could easily adjust them to your needs. Kersey chose a hinged steel hand because it's easy to wear—you can secure it with magnets or pins, and it also provides some space for electronic devices.

Measurement and Adjustment

Of course, a pair of gloves that fit perfectly, wraps around your hands, and is suitable for different movements is what every clothing printing company dreams of! However, considering that everyone's hand size is slightly different, some size adjustments and modifications are needed to the model.

First, Kersey suggested going into Meshmixer and measuring the model. He found the model too small, not to his liking, especially considering he would be installing electronics in it. Most importantly, the model's design made it difficult to move his wrists, with inflexible joints. To address this, he made some modifications to the palm and fingers.

Measuring palm size

While Kersey likes the shape of his hand and the wearable system, he still needs to do some work, adding some thickness to allow enough room for the electronics. This also makes his finger holes larger , giving him room to move his fingers and even clench his fist.

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Install finger parts

While the hands are modeled as a simple two-piece design, the fingers are each composed of three small joints, each connected by a hinge to allow for finger movement.

After printing all the finger parts, Kersey began experimenting with each one, feeling how each finger moved and felt in his hand. Since he wanted to add some rubber parts inside the glove, he decided to upgrade the fingers by increasing their thickness and height . He also suggested creating a master model in Meshmixer containing all the correct dimensions for future use. This way, each time something new is printed, there's no need to readjust the dimensions of all the parts. Instead, you can start printing directly from the master model.

Prototyping using an FDM printer

As mentioned earlier, FDM 3D printing is a great way to do rapid prototyping because it offers a fast, convenient, and cheaper way to iterate! In Kersey's case, this gave him the opportunity to fully test all the glove parts before using the resin 3D printer and to ensure they fit and move well.

Furthermore, FDM 3D printing also allows him to test whether his electronic devices (including new pixels, batteries, and motherboards) are suitable for the challenge.

Once he was satisfied with the FDM results, he was ready to launch his new Sonic Mega 8K (now the all-new Sonic Mega 8K S !!).

✨ 【Related Product】： Phrozen Sonic Mega 8K S LCD Photopolymer 3D Printer✨


3D printing resin role-playing model 3D printing

While FDM printing is more cost-effective, the printed result may not be what you're aiming for in your final role-playing work.

While a smooth surface may be achieved after extensive polishing and priming, resin 3D printed parts can achieve the same look directly from the printer , saving you time and effort.

Kersey appreciates the smooth and clean surface of the printed parts and believes that, thanks to the Sonic Mega 8K's 8K resolution, its quality easily rivals that of injection molding. Furthermore, the printer 's size allows him to print all the parts of the glove on a single build plate, meaning he only needs two prints to complete his gloves.

If you're considering using a resin 3D printer to complete your cosplay costume parts, the Sonic Mega 8K or Sonic Mega 8K S are excellent choices. With high print volumes and an 8K resolution screen, rest assured that all your models will be printed perfectly with a smooth surface!

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