Maker and Veteran Tim O’Sullivan Completes Third Life-Size 3D Printed Movie Character Suit

O’Sullivan with Stan Lee (may he rest in peace)

A project that began as an ambitious therapeutic task for military veteran Tim O’Sullivan after he returned home wounded from combat has evolved into something so much greater. In 2016, O’Sullivan was looking for something to occupy his time after returning home from fighting overseas, and decided to try his hand at 3D printing. He purchased the files for a full-body Iron Man suit, and over the next eight months completed the 3D printed, wearable suit on his desktop Robo R1 +Plus. The end result was amazing, and O’Sullivan was hooked, telling 3DPrint.com at the time that the Iron Man suit would likely not be his last big project.

He took everything he’d learned from the 3D printed Iron Man suit, and by the summer of 2017, O’Sullivan had finished his next 3D printing project: a voice-activated War Machine Mark III suit from Marvel’s Captain America: Civil War. The life-size suit, 3D printed on his SeeMeCNC Rostock Max V3, featured some custom modifications to the files he purchased, and was made out of PETG, with fiberglass added to make the suit stronger. But this additional strength wasn’t for just any old reason – O’Sullivan was finally able to follow through on his original plan and wear the War Machine suit to visit sick children in the hospital.

Tim O’Sullivan with Anthony Daniels

Just like me, O’Sullivan happens to live in Ohio’s Miami Valley region, and I was lucky enough to meet him at the Dayton Mini Maker Faire not long after he completed the 3D printed War Machine suit, which I got to see in person. It was as cool as it looked in pictures, and to my great excitement, O’Sullivan told me that his next 3D printing project would be C-3PO from my beloved Star Wars series.

He reached out to us recently to say “mission accomplished,” and also to share some more exciting news – he and his 3D printed C-3PO suit made an appearance in Chicago for the Star Wars Celebration with George Lucas’s son Jet Lucas, and Anthony Daniels, the actor who portrays the golden droid in the movies.

“Was quite the reward after almost 10-12 months of hard work,” O’Sullivan told us.

“Alot of work went into the suit, much of the suit is a combination of 3D print, real brass accessories (Arm Pistons, eye grills and hand pistons etc.).”

O’Sullivan told 3DPrint.com that it was “an experience of a lifetime” when he was wearing the 3D printed suit at the Star Wars Celebration and got the chance to meet Daniels.

“It seemed to be well recieved based on his expressions,” O’Sullivan told us. “Unfortunately, I never got the chance to explain to him following the encounter on how the suit was made or how it had been a major part of my personal road to recovery.”

Two years ago, the military veteran turned maker told us that working on his 3D printed character suits has been the “best therapy” for him when he was having a hard time sitting still. O’Sullivan also really enjoyed wearing the 3D printed War Machine suit to visit kids in the hospital, and earlier this week he made an appearance at the Dayton Children’s Hospital in his 3D printed C-3PO suit.

“It was absolutely a touching experience for both the parents and children. We walked 2 floors of the hospital,” O’Sullivan told me in an email today. “The suit is the most difficult to wear and always leaves a few bruises, but well worth it.”


O’Sullivan’s detailed Star Wars droid suit is really something, incorporating a voice modulator and 25 watt amp that projects an emulation of the original C-3PO voice. In fact, it’s so realistic that it was accepted and certified by the Ohio Rebel Legion Apollo Base!

“For the upper torso, I had used a 3D scan of the original suit available on Thingiverse and then modified it using Zbrush to clean up imperfections,” O’Sullivan told 3DPrint.com. “I also used a high quality laser triangulation 3D scan of my body from a Human Solutions scanner to match my body frame. The legs were a challenge so I had commissioned Skylu Props who is actually a product engineer to design the 3D model of them to my body scan and have them function/articulate properly.”

O’Sullivan said that Kurt Heydenburg modeled the 3D printed arms of the suit, while Gordon Tarpley modeled the fingers.

“Almost all of the main body parts were 3D printed with the exception of the shorts and feet which were vaccum Formed plastic,” O’Sullivan told us.

To complete chroming on all of the suit’s 3D printed parts, O’Sullivan himself used a hydrochroming process (Angel Guilding Products), which is essentially “real silver sandwiched in between 2 layers of clearcoat on top of the 3D print,” with a layer of gold-tinted clearcoat to cover on the top.


While most of the 3D printing for C-3PO was completed on Rostock Max V2 and V3 printers, I learned that he has just upgraded to SeeMeCNC’s new Boss Delta system. I wonder what life-size 3D printed suit he’ll make with it…if he’s taking suggestions, I’m voting for Batman!

Discuss this story and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below.

[Images provided by Tim O’Sullivan]

3D Printing News Briefs: August 10, 2018

We’ve got some business news to start things off with in today’s 3D Printing News Briefs, followed by a little research and a really cool 3D printed costume. The Department of Defense has awarded a contract to Contour Crafting, and Sutrue is celebrating its tenth anniversary. Facebook has made the decision to ban blueprints for 3D printed guns, and a Siggraph paper takes an in-depth look into near-eye displays. Finally, several companies helped the non-profit organization Magic Wheelchair make a really cool 3D printed wheelchair costume for a big Star Wars fan.

Contour Crafting Receives Department of Defense Contract

One of the first methods of large-scale 3D printing, Contour Crafting, uses large but lightweight robotic 3D printers, which can quickly put down layers of building material to rapidly create entire buildings onsite in just days. The California-based corporation itself is on a mission to commercialize disruptive construction technologies, and we recently learned that the US Department of Defense (DoD) has awarded Contour Crafting a $3 million research and development contract to build a concrete 3D printer for the purposes of building construction for disaster relief.

According to the company’s website , “Effective 25 JUL 2018, the Department of Defense has awarded Contour Crafting Corporation with a Rapid Innovation Fund contract in the domain of large and construction scale 3D printing. The outcome of this funded R&D program is expected to be a technology which, among other applications, will effectively respond to disaster relief situations with expedient, safe and sustainable structures and buildings.”

This information confirms that the DoD is not putting all of its eggs into one basket, so to speak, and is seeking outside help for its construction 3D printing goals.

Sutrue Celebrates Ten Years

Medical device startup Sutrue first started working on a 3D printed suture stitching device to help prevent needle stick injuries back in 2014, and became the first company to successfully 3D print a suture device. But Sutrue’s story actually began back in August of 2008, when its founder Alex Berry was stuck at home with a broken ankle and watched a documentary that provided some insight into robotic suturing. In an effort to keep busy during his recovery, Berry, who had some basic CAD knowledge, got to work.

After moving to the UK, Berry officially started Sutrue in 2012, meeting some influential people along the way who helped him get closer to achieving his goal of creating a 3D printed suture device. The startup completed a £30,000 crowdfunding campaign in 2014, submitted another patent, developed a few mutually beneficial relationships with other companies, and secured further funding for continued device development. Now, Sutrue is celebrating the 10th anniversary of Berry’s initial idea.

The startup wrote in a post, “It’s been ten years of ups and downs, filled with much uncertainty particularly in the first five years in which Berry didn’t even know for sure that the device would work. He has maintained the progression of the device through having a healthy dose of insanity, extreme resourcefulness, and an inquiring and problem-solving mind. He’s gone against many societal norms to have created two working prototypes of his automated suturing device – the robotic and the handheld, but as the route to market becomes closer and closer, he’s glad to have fought against the odds to see the project through to completion.”

Facebook Bans 3D Printed Gun Blueprints

Gun with 3D printed parts. [Image: CNET]

There’s been an increased amount of conversation on the topic of 3D printed guns recently, after news broke of a settlement between the US State Department and Texas open source 3D printed gun designer Defense Distributed, run by Cody Wilson. The settlement states that Wilson and his non-profit organization can publish files, plans, and 3D drawings of guns in any form, and are also exempted from export restrictions; additionally, the government will be paying nearly $40,000 of Wilson’s legal fees. This means that people who weren’t legally able to purchase firearms before, such as felons and domestic abusers, can 3D print their own guns without serial numbers. As you can imagine, many are not happy with this decision. This week, Facebook, the world’s largest social network, said that it will ban any websites that host and share blueprints of 3D printed guns, though the designs have already been available online for years.

According to BuzzFeed News, a Facebook spokesperson said, “Sharing instructions on how to print firearms using 3D printers is not allowed under our Community Standards. In line with our policies, we are removing this content from Facebook.”

MSN reports that Facebook did not “immediately respond to a request for comment regarding the Ghost Gunner” 3D printed gun.

Siggraph Paper on Optical Design for Augmented Reality Near Eye Displays

This year’s annual conference on computer graphics, SIGGRAPH 2018, starts this Sunday, August 12th, in Vancouver. One of the papers published for the conference, titled “Steerable application-adaptive near eye displays,” discusses see-through near eye displays (NED), which are currently being used in the Hololens, among other things. According to the Stanford Computational Imaging Lab, most NEDs work by using a stereoscopic image pair to optically drive the visual system’s vergence state to “arbitrary distances,” but drives the focus (accommodation) state towards a fixed distance.

The technology is a bit of a long shot, due to people getting motion sickness or their eyes getting tired, but if we can get it to work, I bet every movie theatre in the world will employ it.

The abstract of the paper reads, “The design challenges of see-through near-eye displays can be mitigated by specializing an augmented reality device for a particular application. We present a novel optical design for augmented reality near-eye displays exploiting 3D stereolithography printing techniques to achieve similar characteristics to progressive prescription binoculars. We propose to manufacture inter-changeable optical components using 3D printing, leading to arbitrary shaped static projection screen surfaces that are adaptive to the targeted applications. We identify a computational optical design methodology to generate various optical components accordingly, leading to small compute and power demands. To this end, we introduce our augmented reality prototype with a moderate form-factor, large field of view. We have also presented that our prototype is promising high resolutions for a foveation technique using a moving lens in front of a projection system. We believe our display technique provides a gate-way to application-adaptive, easily replicable, customizable, and cost-effective near-eye display designs.”

Co-authors of the paper are NVIDIA Corporation‘s Kishore Rathinavel, Praneeth Chakravarthula, Kaan Akşit, Josef Spjut, Ben Boudaoud, Turner Whitted, David Luebke, and Henry Fuchs from UNC Chapel Hill.

3D Printed Star Wars Wheelchair Costume

Here’s something fun and heartwarming to kick off your weekend – non-profit organization Magic Wheelchair, which makes free, bespoke wheelchair costumes for kids, created a 3D printed Poe Dameron X-Wing Fighter wheelchair costume for a 13-year-old, wheelchair-bound Star Wars fan named Vedant Singhania to wear at last month’s Comic-Con International. Project partners included Pixologic, which used its ZBrush digital sculpting software to provide the design and modeling work, and Dangling Carrot Creative, which used the high print speeds of the Massivit 1800 3D printer to make 50 separate costume pieces in a little over two weeks. Massivit also donated 3D printing materials, and Monster City Studios assembled the large wheelchair costume.

“We connected with Magic Wheelchair because we knew our technology and modelling expertise could assist them with the fantastic work they are doing for children in wheelchairs,” said Pixologic’s 3D Product Development Manager Paul Gaboury. “After we designed the costume, Dangling Carrot Creative was the final piece to the puzzle. The company allowed us to 3D print life-size to help remove the need for molds or casting which saves substantial time and money.”

Discuss these stories, and other 3D printing topics, at 3DPrintBoard.com or share your thoughts in the Facebook comments below. 

3D-Printed Death Star Enclosure for Your Pi 3 | #StarWars #enclosure #piday #raspberrypi @Raspberry_Pi

This is a cool case from Furnibird on MyMiniFactory – the enclosure is pretty simple and could easily be developed upon with internal or external accessories and designs (think blinking lights or audio files that play when you do something in the OS):

Maker Darren Furniss, who goes by the username “Furnibird” online, has created a created a 3D printed Death Star to house a Raspberry Pi 3.

When we spoke to Furniss he told us that the print was created in Fusion 360, a programme he learnt from watching YouTube tutorials.

The design process took three weeks and had to incorporate some kind of closing mechanism. Instead of a hinge on one side, the top and bottom sections slide lock into place. Some screws are required to keep everything together, including the stand which is needed to stop your Pi rolling away.

check out the files here at MyMiniFactory – via makers.htxt.africa



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