Lighting Up 3D Printed Cosplay

Our April Hacker of the Month is an incredible cosplayer from Cambridge, Massachusetts who goes by the identify of Spoon Makes; Alina Granville.

As a younger woman rising up, Alina was given the Spoon moniker in grade college when mysteriously, a spoon flew out of her lunch field a lot to the amazement of her friends. As she grew older and started to create issues, particularly cosplay and props, she added the Makes because the second portion herself.

Alina’s first introduction to 3D printing was for an structure class venture again in 2009. She was capable of print one part of her design on a powder-based, Z-Corp printer. After this, she continued to dabble in 3D printing for architectural design, broadening her efforts on Stratasys printers as nicely, however she actually didn’t begin getting severe about 3D printing cosplay till 2016.

“On the time, the prop I used to be making had a really difficult formed tail that wanted to be glued to a vacuum, so I printed my solely PLA prop ever on an Ultimaker2. The opposite half of the prop was carved from XPS foam sitting on my kitchen ground. My residence isn’t sufficiently big for tons of hand constructing and the mess it generates, so 3D printing appeared like the way in which to go sooner or later.”

At present, she prints with a customized Core-XY printer with a construct measurement of about 310x410x350mm – roughly based mostly on the D-Bot construct, it makes use of linear rails as a substitute of wheels and a direct drive BondTech v6.

“It is design was pushed based mostly off my printing preferences and my want for producing props and cosplays. On the time I used to be in search of a method to 3D print some outsized clear versatile boots for my Torbjorn construct, so my fiance and I constructed it final spring/summer season to make the boots… it is our first private printer! We might have purchased one thing off the shelf, however nothing actually suited my wants in an affordable worth vary and it turned out to be an incredible expertise and never too difficult. The method taught me how printers labored and since I understand how the whole lot goes collectively it’s manner simpler to troubleshoot or make adjustments. I additionally recurrently borrow a Flashforge Creator Professional; it is nothing fancy however it reliably will get the job accomplished. Every now and then, components can be printed on a Markforged with nylon if a component must be a mechanically practical.”

Alina likes to make use of ABS primarily due to its energy and skill to be welded. Final 12 months her focus turned to clear colour ABS, which was good for her Torbjorn cosplay as a result of there are few different supplies which can be structural, translucent, inexpensive and light-weight. She began to print with nylon for her cosplay, however she experiences that the ending choices are extra restricted than ABS, and rather more technically difficult for printing giant cosplay objects. Due to her affinity for translucent ABS, her preliminary prop was a glowing sword for a Saber Alter cosplay. She additionally used translucent ABS and TPU primarily for her Torbjorn cosplay with numerous ending methods for the totally different elements:

“Since I exploit ABS my ending methods differ from most cosplayers that use PLA, in comparison with them I exploit rather a lot fewer putties, fillers, and primers. My major post-processing technique includes a mixture of sanding and bushing on acetone to easy and refine the prints. I’ve tried passive vapor sprucing, however it did not work that nicely for cosplay; there are points becoming bigger components within the contained vapor, the vapor would not evenly distribute on all faces, it takes a very long time to dry, and it simply blurs all of the element. Whereas labor intensive, brushing on acetone and permitting it to evaporate works nicely for me with out eroding the small print and the sanding mud appears to assist easy the print (additionally as a plus the acetone appears to bond the layers collectively higher). I am going to normally end with 1-2 layers of sandable/filler/auto primer earlier than paint, nevertheless, I had fantastic outcomes skipping primer on my Torbjorn construct. I avoid utilizing an excessive amount of primer, it erases particulars and too thick layers are simple to chip. For becoming a member of items collectively I additionally use an acetone ABS juice, it is my go to. I do know lots of people like to make use of a thicker slurry, however I work with a skinny consistency – it dries quick and would not get gummy; the bottom line is to use sufficient layers of the skinny juice to soak/soften the components earlier than urgent them collectively. To repair gaps, cracks, and seams I’ve began utilizing a 3D printing pen, adopted by the brushed on acetone to weld it to the half, then sand it degree with the print. I am going to nonetheless use the filling putties if vital or to be faster, however there is no must waste as a lot materials slathering it all around the print to sand it off. For components with glowing bits I discovered it’s best to avoid putties and sanding layers of primer. Even opaque filaments can have gentle bleed so something with uneven layers could be seen beneath the paint. Ending TPU, however, is a wholly totally different beast, which I have never found out any superb constant answer but, proper now I have been utilizing a soldering iron and totally different versatile coatings and paint. One other enjoyable method I exploit on some items is dye! It is a great way to paint translucent items if you do not have an airbrush.”

Alina’s cosplay characters up to now have been picked from some glorious sources, lots of which come from Blizzard Leisure; Nova from StarCraft/Heroes of the Storm, in addition to Mei and Torbjorn from Overwatch. She has additionally accomplished a cosplay for Saber Alter, an anime tackle the legend of King Arthur.

“In cosplay, there are such a lot of totally different methods and supplies persons are utilizing. The primary cause I deal with printing is that it’s comparatively compact. Residence dwelling is relatively tight, there is no storage or yard, there is no devoted messy area, there are not any further tables for giant molds to remedy. Printing, however, takes up rather a lot much less area, simpler to retailer filament spools than different supplies, is, for probably the most half, an additive course of (versus carving foam with a knife or Dremel which make a giant mess), and as a plus produces light-weight, extremely clear and detailed outcomes.”

As to why 3D printing is such a big a part of her course of for producing cosplay props?

“When it comes to cosplay, it permits me to provide a clear product with excessive accuracy and element. The ultimate product is sturdy and may stand up to the excessive stress touring, sitting in sizzling vehicles (do not strive that with PLA!), and the pains of conference accidents (had a prop take a 5’+ fall onto tough concrete and all of the epoxy joints broke however the print was solely evenly scuffed up), all whereas being comparatively light-weight. There are many different supplies utilized in cosplay like EVA and XPS foam, worbla, and thibra, and casting resins…however I see 3D printing as a center floor between all of them by way of worth, weight, energy, and ease of use.”

“I additionally say the printer is like an additional set of fingers. It is nearly like I can double my work time since I can spend the time modeling, then whereas it is printing I can work on different issues! Nonetheless, I personally do not feel 3D printing hastens the cosplaying course of considerably if something focusing solely on printing is slower than working by hand (attributable to lengthy print occasions and coping with print striations). Most individuals are utilizing private printers for printing very small and detailed issues, however cosplay is giant and detailed. I am prone to spend further time perfecting my fashions from references after I’m working in CAD, then if I used to be strictly working by hand the place I is likely to be extra forgiving if it is not as correct. However ultimately that pays off and may have some very skilled outcomes! Should you’re sensible about it and work with a number of supplies, 3D printing can actually pace issues up when you use it to print detailed tedious components and use easy flat inventory to make the remainder. Working by CAD and 3D printing could be actually useful at occasions for mockups, it is simple and fast to print off smaller variations of fashions to simply wrap your head round complicated designs or print small sections to verify match or joints. That is one thing cosplayers must do extra usually as 3D printing could be unforgiving with errors. Relying on the ‘anatomy’ of the print, you’ll be able to’t simply lower a mannequin shorter or warmth it into form to make it work like different supplies.”

3D printing has allowed Alina to provide superb cosplay on a good price range – one thing cosplayers are infamous for. She experiences that with out the entry and low-cost availability of translucent ABS filament, her Torbjorn costume wouldn’t have been potential.

Among the finest issues about utilizing 3D printing in making her superb cosplays is the success of the costumes and props and the overwhelmingly constructive suggestions she has acquired – it retains her coming again to do it repeatedly!

What cosplay is up subsequent for Alina? If her FaceBook web page is any indication, it seems to be like she can be going for the most recent character to hitch the Overwatch line-up, a feminine engineer named Brigitte, who occurs to be the daughter of Torbjorn!

For the long run, Alina is engaged on performing some fee items, in addition to beginning a line of how-to movies on her manufacturing and ending methods for her wildly profitable cosplay designs. We are able to’t wait to see what she desires up and creates subsequent, and we look ahead to following up together with her sooner or later – good luck Alina!

Wish to be our subsequent Hacker of the Month? Electronic mail chris.morgan@matterhackers.com, and inform us about your 3D printed creations – you may be featured in our subsequent e-newsletter. Hacker of the Month wins 3 free spools of PRO Collection PLA or ABS filament to additional their pursuit of 3D printing greatness!

Hero picture courtesy of John Jiao