Elysium Max Exoskeleton

Today Ligature Marks released a metal music video featuring this exoskeleton:

Some production shots:

I took the exosuit to Wasteland Weekend, and only encountered minor inconveniences like bolts loosening and falling out. I would say the exoskeleton is now totally wearable and can be considered completed.

Some progress shots from working on exo gloves and reinforcing various parts of the exoskeleton. Most of this work was done during the winter, and relatively minor work is still left to do. The project is on hold until the work space opens.

Repairs after NW Wasteland Decompression party. Replaced plastic rod ends with steel ones from McMaster Carr, electrical wiring in the spine with bungee cords. Replacing finger connectors with elastic straps as well to make the suit appropriate for extended wear.

I got to wear the suit to Wasteland Weekend afterparty (did not make it on time for Weekend itself):

This is the last week of painting, next I have assembly and tuning.

I finished casting all the required parts mid-July and moving onto finishing & painting. So far it's been a month of finishing all the cast parts by using metal filler and modeling primer to sand over imperfections, as well as using a rotary tool to clean up tiny details. I expect much less effort to be required for machined parts. No idea how much time painting will actually take after all the parts are primed & polished.

In other news, I presented this project to high school students at the Pacific Northwest College of Arts:

3D Printing to Metal Casting: Making of Elysium Exoskeleton Prop

This weekend I made a second attempt at casting chest & shin plates. For the next one I will use thin sprues in addition to thick sprues to prevent parts of the model from breaking off with the sprues.

Wax parts before dipping to build shells around them:

First attempt:

Second attempt:

Both put together, before cleanup:

I will make another attempt at casting the chest plate to see if I can get it even cleaner, and then redo one of the shin plates before there wasn't 100% fill.

The last mold required to finish this project! There are some optional parts left to make molds for that I might do if I have time left before the Wasteland Weekend.