Today we focus on the innovative and jaw dropping creation of James Bruton who brings to the table an Alien Xenomoprh suit. This suit is being completely 3D printed and designed from the ground up. The Cosplay industry is slowly turning more and more to 3D printing as it becomes a way in which people can turn their wildest dreams into reality.
Meet the Maker: James Bruton
James Bruton is the author of the esteemed XRobots.co.uk and its associated YouTube channel. He builds Sci-Fi props and costumes using 3D printing, electronics, as well as traditional techniques such as sculpting, moulding & casting. He is also a trustee of his local non-profit community Makerspace in UK Southampton who are also one of our registered Hubs.
The Build
The original idea for the print came from Oscar winning set designer, sculptor and surrealist painter H. R. Giger who was the original mastermind behind Aliens creation from the famous film series. James had previously played with the idea of building an Alien suit before he owned a 3D printer but the build became too time consuming as it would have to be built from rigid clay casting and rubber moulding. When James received his 3D printer it opened up the door to finally allow him to have a crack at it but this time with an approach that allowed for more flexibility and with a margin for failure.
A 3D printer’s capacity is limited compared to molding, so one of the biggest challenges for James was being able to create a jigsaw of parts that all fit neatly together whilst still maintaining the overall mobility and look. He did this by fitting his Lulzbot TAZ 3D printer with an innovative dual extruder which allows not only the ability to print standard filaments like ABS or PLA but also Ninja Flex (rubber like flexible material) at the same time. This experimental method allows for amazing results when creating any kind of Cosplay thanks to the solidness of the print coupled with the ability to move unrestricted whilst the wearer has the piece on.
The dual extruder works by being cut through Slic3r or can be exported through other software using the multi material option when saved. Up to this point James has built the arm and forearm piece which are already looking ridiculously impressive. You can see in the video where the dual extruder worked its magic by fitting two flexible points of articulation onto the hard plastic body of the piece. The hands were given the dual extruder treatment as well allowing for the main body of the hand to be flexible in its use giving the wearer a comfortable and controlled feel whilst the viewer sees a less rigid more realistic movement from the hand.
This build truly shows what can happen when a skilled designer is coupled with 3D printing and we cannot wait to see how the entire suit turns out.
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