OUR MECHA COSTUMES

Each costume is made in a three stage process. The molds were designed digitally, first in 3D, then exported and tooled for appearance and accuracy in a 2D Suite, before being printed, cut, assembled, and poured in a silica composite material.

The poured Mecha-Mold is then inspected, checking against resources to ensure accuracy, and to check for any anomalies, or defects. Then the Mecha-Mold is given final sculpting details, and then goes on to be sanded, detailed, and coated in a protective resin, which- after curing, is (once again) sanded, and detailed. We take pride in our costumes- each costume design is the result of well over 3,700 hours of work.
 
We will make only 200 copies of each costume- each costume will be individually numbered, given their personalized manual and certificate of authenticity. After the 200th costume is cast and finished- the molds will be destroyed.
 
Each suit is now over 160 parts.. Not counting wiring, lights, etc.
 
BASE MATERIAL:
 
Composed of highly durable plastics polymers- the same polymers that are used in many auto-body kits, cell-phones, high-impact luggage, and more. It has an excellent resistance to impact and is very tough. 
 
We chose plastics polymers, for their mechanical strength- it's dependability, and it's vote of confidence from mechanical and industrial designers across many industries.
   
Stage 1- FORMING AND CONNECTIONS:
 
Each piece of each costume starts life as ambiguous, unassuming pieces of plastic polymer sheeting.. It is then thermoformed on our vacuum-form table into a piece of Mecha-Component perfection. Our newly born Mecha-Component is then cut, it's edges sanded- and any connection bits are added. It is then ready to head on over to the Painting area..
 
Stage 2- PAINTING STAGE:
 
We employ a five part, airbrushed paint job- much the same as an automobile paint job. We start with the base coat on the outside. Then we apply two to three coats of color- achieving a smooth, solid, glossy surface. We finish the paint job with two coats of clear coat paint- sealing, and protecting the parts for the final stage.
 
Stage 3- REINFORCING STAGE:
 
Our final stage, prior to shipping- is to reinforce with two even coats of fiberglass epoxy resin. Yes- we reinforce and protect our suits with a minimum of two even coats of fiberglass resin. This helps ensure that any accidental droppage, or mistreatment will not result in damage to the Mecha Costume. It also makes for one pretty final product.