• Custom sewing and patterns

• 3D printed silver accents

• functional body protection

• multiple materials

2017

Oh boy has this been a long ride. This Captain America suit started in early 2013 and has been progressed and updated on and off since then. It started as the Stealth suit seen early in the film: Captain America the Winter Soldier. Shortly after, this suit was torn apart to update the colors and construction to match the newer films sporting Captain Rogers more “spangly” color scheme.

The majority of this suit is constructed from duck cloth, similar to a canvas backpack type material. This provides a very nice rigidity to the suit and also the texture/feel of American military textiles. There are also several sections that utilize a waxed canvas which was recycled from this suits previous version, and provides a nice contrast of material without drastically conflicting with the overall aesthetic. As a replacement to the leather looking parts of the original design, upholstery vinyl was added in necessary areas. Sections that require more flexibility, such as the torso base layer (connecting the sleeves to one another and the wearer), are made of a cotton stretch material (similar to stretchy active wear material). I suppose it’s fairly important that this character can reach around to his own back.

The silver accents on this suit have all been 3D printed and finished with a metallic paint to give the illusion of metal. They are made from PLA, a common plastic used in consumer 3D printing systems that provides strength and detail. This suit has also been outfitted with elbow and knee protectors similar to those used in various sports. They provide a functional and realistic look to this combat suit and assist in the alignment of the sleeves and pant legs.

Overall, this project took 5 years to complete and seems to be continually updating. At one time, there existed a helmet and shield to accompany this costume, but they have been deconstructed and redesigned to better match the feel and look of this costume. The original shield was constructed with thermoplastic and a system of magnets (more about that shield can be found in the miscellaneous section). The original helmet was scrapped together form an old store-bought silicone helmet, and sections of thermoplastic painted black. Both the helmet and shield are still in development using techniques of molding and casting to ensure the best material and function of multiple copies. Kit versions of these items will hopefully be available soon in my Etsy shop.

One day this suit will come to its final form. With the development of a new shield and helmet, hopefully that day will come soon. Below you will find a gallery of photos taken during the construction process. Please, enjoy.

-Zach