The Nerd Series

Working Iron Man Costume Made Using 3-D Printer By Marvel Fan

Fiction July, 04, 2025

Caio Cesar, a 30-year-old comics fan living in Campinas, near to São Paulo in Brazil created an iron man costume using a 3-D printer and it works as well. He shared that it was the first time he tried stuff like this and is incredibly happy with the results. He shared, “I had never cosplayed before, but I always had the desire to bring the armour that appeared on the movie screens into my home, but without spending a fortune.”

He further shared “So, I decided start with this challenge shortly after purchasing my 3D printer, and wanted to make the armour as close as possible to the films. It’s just my first suit, and I think I’ve achieved my goal.” But it is not as easy as it sounds. Caio had many obstacles to make his iron man suit with the fittings, supplies, and many more stuff.

He shared “Initially a big difficulty was convincing my wife that I was using the credit card for printer supplies! Just kidding – the biggest difficulty was adjusting the armour to my body because, to make sense, it couldn’t seem that it is much bigger than me, or that it would be crushing me. The original armour is around 1.88m, but I’m 1.60m so making the scale was very important to obtain a good result.”

He further explained “I also had to calculate the internal space for lights, wires, motors, circuits and also the ‘shock’ points, so that I could move in a satisfactory manner. Another difficulty that appeared in the middle of the journey – which was my fault – was that I accidentally dropped the chest plate on the floor and it broke in half. That made me lose some time.”

He shared “I printed this entire outfit with just one printer, and if you know Brazil, you know how things are much more expensive here and not all material is easy, so you always have to be looking for alternatives. I started this project in June 2019 and in fact ended in November.”

He shared how he made use of the extra time he had on his hands because of the global pandemic. He explained, “I had the opportunity to go to just one local event to present the armour, but after that the pandemic started, so, I continued to improve the costume so as to surprise when everything normalises.”

He tried the costume for the very first time in an event and shared the memories of the day. He shared that he had 20 minutes to cross the lobby to get to the room to present himself but the problem was that everybody stopped him. He had clicked 400 pictures in 20 minutes and missed the event. He will start working on a suit for his wife now. And the suit will similar to Pepper Potts from the comic.

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