Iron Man Exosuit Creation Process

Introduction

• Presenter: Alex Burkan
• Topic: How to create the outer layer of Iron Man exosuit
• Overview: Process from sketches and clay models to full-size composite version

Background

• 6 years of experience in building the Iron Man suit
• Initial development started with electrolysers:
  • Split water into hydrogen and oxygen for fuel
  • Used as a powerful compressor for artificial muscles

Design & Planning

• Begin with pencil sketches:
  • Helps understand the geometry and interactions of parts
• Importance of detailed notes in a diary for final device functionality
• Move to creating 3D models using software (Blender, 3D Max, Z-brush) or traditional clay sculpting

3D Scanning

• Transition from smartphone scanning to high-resolution 3D scanners
  • Improved precision and detail capture of models
• Importance of post-processing models for 3D printing

3D Printing Process

• Steps involved:
  1. Retopology for 3D printed parts
  2. Slicing parts for printing
• Printing considerations:
  • Thickness for strength
  • Infill factor between 5-50% for load-bearing parts
• Use of composite materials for increased strength

Composite Reinforcement

• Duration: Several months for helmet and torso
• Testing various materials (fiberglass, carbon fiber, Kevlar) for optimal strength-to-weight ratios
  • Document testing results in a table
• Experimenting with coating properties for durability:
  • Hardness, abrasion resistance, repair ease

Final Assembly

• Process of reinforcing parts with templates using paste and brushes/rollers
• Importance of achieving a smooth finish:
  • Sanding, priming, and applying coatings
• Attaching composite parts to the metal exosuit

Conclusion

• Emphasizes the fusion of man and machine
• Encourages continuous personal development while building the suit
• The described technology is the most optimal for creating complex devices
• Vintage building instructions available for members on Alex Lab channel

Final Thoughts

• Thanks to the supporters for enabling the project
• Reminder to like, share, and join Alex Lab for access to resources
• Wish luck for viewers' projects and encouragement to stay connected