So first, I did not make the model. I recently obtained the model and am in the process of adding detail and making the model 3d printable.
This is a massive project and will probably take more then a year.
The end product will hopefully be a lifesize, wearable, self standing, and actuating power armor frame from fallout 4.
There are currently approximately 50 separate major pieces and over 8000 polygons.
If I spend one week per piece (an ambitious pace) it will take me at least one year.
One day to desighn, and 3-4 days to sand.
I will try to update this thread at least once a week. Feedback is welcome and critical to the success of the project. Don’t hesitate to point out details I have missed. I will also post screen captures for reference.
First week’s major piece will be the right hand. The model’s hand is unsurprisingly unrealistic. The fingers are all the same exact mesh and are the same size. The thumb is even a copy of the three joint finger.
I work with 3d printing myself in the spare time, so i can give you some pointers
never use smooth shading when working with 3d prints, it gives misleading visualization when making the project
STL files always reduce the model to tris, so 3d printing is a bit more lenient in termos of topology, but it MUST be manifold.
Avoid overhangs (slopes) as much as possible.
You can save a lot of material and printing time if you take parts that look like regular household or maintenance items and use it together with smaller 3d printed parts: they’re both sturdier and cheaper.
Main example in your case is PVC Pipes and old shoes.
Some of the larger pieces will be re-casted in resin so that it’s a single stronger contiguous piece. There will also be hidden aluminum support since aluminum will be better weight to strength ratio. The foot petals will have to support a 200 pound person(me) plus 50 lbs suit. Hopefully I will find a way to add an easy detachable harness so the weight can be transfered to my torso. I did find something very interesting while trying to scale the hand. I was trying to scale the armor so that my hand could fit and came to the conclusion it was impossible. Upon further inspection of a different model, I found the character doesn’t actually put thier hand into the glove but rather holds a handle. You can see that in the following photo.
You can always adapt what don’t fit the reality. the whole hand thing is over-engineering for a cosplay, and would make even basic movement harder (imagine holding a glass of water with it).
