Monday, November 7, 2016

Adam Jensen 2.0 Deus Ex Mankind Divided

In 2012 I did Adam Jensen from Human Revolution: Deus Ex Human Revolution AJ Costume

When they announced a new Deus Ex game, I was psyched! Then I saw that they were making a new Adam Jensen suit. Pfffft! Not at all surprising, so here we go:

 (More final pics at the bottom)

Some project notes:

This project started officially in preparation for Halloween 2015. Because of how little time I had between the game's announcement and Halloween, I only had time to make the vest and utility belt.
I ended up using the Human Revolution arms.

After Halloween 2015 I started to work on new Mankind Divided arms in preparation for my first San Diego Comic Con (2016) which was in late June.

I'm was happy with the results, but it was super-uncomfortable to wear all day and I ended up ripping the upper arm muscles.

After SDCC, I started redesigning better fitting forearms for 3D print, and doing the upper arm muscles again -this time more durable.  This was in preparation for Halloween 2016.

To be honest, I'm not sure how much more comfortable everything was! At the moment, I'm thinking about redesigning the forearms to be completely out of foam. This would be in preparation for SDCC 2017.

...yeah I don't know when I'll stop working on this project and wearing it to events. I really love the  Adam Jensen character, and all the Deus Ex games. Plus I can sort of pull off looking the part. I can't stop! One day I will figure out how to do extending arm blades.

Because of that time crunch,  I didn't take many pictures of the "vest" construction.
Here it is completely assembled Mod Podged, Plasti-dipped and primed.


All the hardware for the vest which includes a bunch of parts I modeled and 3D printed.

Completed vest.

Starting on the upper arm muscles:

I shaped them with a Dremel and a stationary belt sander.

Adhesive-backed carbon fiber vinyl wrap (from Amazon)


Both Deltoids:

One half a bicep:
 Triceps all wrapped up:

Starting on the upper arm "cuff" to which all muscles are attached:

Starting to glue the muscles to the upper arm cuff:

Almost there:


Just some of the iterations for the Mankind Divided versions of the forearms.
On the left in blue is the Human Revolution version which I used as a starting point.

Further iteration:

Here are the parts that ended up getting 3d printed:

Painting the forearm and finger parts:

Assembling the hands. This was tedious AF. Not as tedious as taking each flat finger piece and using a hairdryer to soften the PLA then bend each of them around my fingers though. -The number of times I burned my fingers with hot PLA or had super glue soak through the glove and stick it to my skin. 

Very happy with how they came out though:

Combination of magnets and snaps to attach the top forearm piece:

These forearms came out much better than my first iteration (which I took to SD Comic Con 2016) They were super-uncomfortable. Like having super-tight handcuffs on all day. 

These are a bit bigger all around and go on my arms smoother. Still, I think in the next iteration, I will use thinner elastic and loosen it a bit. It was really annoying trying to fish my hand through those straps.

My least favorite part. Sewing. -But I don't have access to a sewing machine, so "super-glueing."
That's right, I super-glued each piece of vinyl to make the belt pouches.
Still least favorite, and it only came out "OK."


San Diego Comic Con 2016 Meetup hosted by Bill Doran (Punished Props).
Bill Doran (evil ted shirt) ............................................................Punished Props
Ted Smith (behind bill)................................................................Evil Ted Smith
Jason Biser (Comander Shepard).................................................Biser Builds

Turns out Deus Ex: Mankind Divided was being shown at SDCC. That provided for some neat pics.
And they gave me a lanyard! Yup! A lanyard!

Pretty sweet shot over my shoulder over Adam Jensen's shoulder in game.

The Square-Enix lanyard:

Photos by Damon Wilson-Hart

Monday, March 21, 2016

Destiny: Monte Carlo

Modeled in 3DS Max and Zbrush:

All the parts as designed to be properly 3D printed:

And here are all the parts 3D printed temporarily taped together (also an in-progress Hawkmoon):

After a ton of spot putty, filler primer and sanding, I've started spraying the main parts a glossy white:

Test fit:

 All the parts painted the appropriate colors:

Now with a graphite shine! (on the gray metal parts)

As seen at the top of this post, I think this came out pretty awesome. Very happy with it.

After a few months sitting on my desk at work, I took Monte Carlo apart and took it home to begin making molds:

In several instances I had to fill deep holes with clay

Sand, prime, fill, sand, prime, fill, you know the drill (heh heh)

 Box molds for the smaller parts:

Finished molds with silver dust. Ready to cast.

Since there are some super-detailed areas on MC like the feather engraving on Hawkmoon, I decided to take special care  with the molds on those parts. I just used my finger to push the silicone into the engravings on these parts.

This process takes longer but it ensures a better mold in the end

Here's the first cast. I think it came out really well. The engraving is perfect. (Except for that air bubble right below it lol).

Pouring high to get rid of air bubbles for the magazine mold. 

For the bayonet mold I wanted to try a new method intended to save silicone. 
I followed this 2-part video tutorial: Hold to Mold a Prop

Again, pushing silicone into the tiny recessed details .

Wait a second! Where's the silicone in the engraving from before?
It took several attempts to make create a good mold setup for the bayonet. I had ripped out that thin silicone, and once I had a good setup (as pictured below), I re-did the silicone in the engravings.

Blocks of silicone from (very old Lancer paintball gun molds) used as registration keys for the fiber glass mother mold.


Once the mold was done, I noticed a big problem (not pictured). The silicone on one mold half was too thin so the pink silicone blocks kinda weighed on the side walls a bit. The result was that when the mold was closed up for casting, one side-wall of the bayonet was wobbly.

Regardless and with my fingers crossed, I pulled a cast:

The results were OK. There was some wobble along one side wall, but a quick sand, made 'em disappear. If they continue to come out serviceable, then we're good to go. If they prove to be a problem, I'll have to re-make this mold :/

Upper receiver top mold.

Because the part has a large undercut (the shaft for the bolt), I poured silicone first into that channel.
This made sure that  I wouldn't get any air bubbles in the mold which were a risk had I just poured silicone over top in one go.

 Next part:


At this point 11/24/2016 I'm out of silicone. I went ahead and prepped more parts for molds, but now I'm waiting to pick up some more. 

 Upper receiver:

Stock mold:

Ok, I got more silicone, so here we go!

I also pulled some casts from the other molds which I'm relieve to say, worked out nicely:

Sight rail mold:

After the silicone cured, and without removing the master model, I made a support structure from strips of masonite.  I didn't take a pic of the finished structure (I may add one later here), but it ended up looking like two right angle corners that I clamp together.

I added that "tab" of foam core to this mold to save a bit on silicone. It seems a little silly in retrospect, but I was hoping that I could finish all the molds with this last 10lb kit of silicone...

...I was wrong. I ran out again. <sigh>
I have one half of the grip mold and the entire mag-well/lower receiver left. So until I get more silicone...

We're almost done! (02/04/2017)