Sta.sh
I first began with a human form that closely resembled me from a free software program called MakeHumman.
Using the best reference images I could find I modeled each piece of armor in 3DS Max starting with low poly proxies and adding more level of details. I did NOT download files from a shareware site or any other source.
Next I printed the armor with my 3D printer. The material is ABS plastic. The software divides the imported model into layers .007 if an inch thick and prints the part one layer at a time. This costume was 64 prints and about 500 hours in print time.
The raw prints are somewhat rough and you can see the layers of plastic. I coated the parts with black abs glue found at any hardware store. This filled the gaps and made the parts stronger. The glue was sanded down to give each part a smooth finish. Then I primed, fixed spots, primed, sanded, painted and then finally clear coat.
The Eye on the sword, detailed accents and stripes were created in Photoshop and printed out on water decal paper and then applied.
The outer tan strapping was two pieces of ultrasuede fused together (to add thickness and get the nap even on both sides), cut into strips and the braided together. The buckles they are attached to were also modeled and printed.
The eyes were silver sun glass lenses with white see-through fabric over them.
The body suit was crafted by my mother and she also helped me with the interior strapping that holds the armor together
