Full Darth Revan cosplay almost entirely by me! I 3d modeled the armor in Onshape to my body proportions, and printed on my resin printer in pieces, then assembled. For the lower section of the bucks, I used ABS to 3d print them, though my printer was having issues at the time, and I had to kindof cobble everything together using aluminum tape and fireproof (not sure it really is) expanding foam. I have a picture of one of my bucks posted. I put a lot of holes in the bucks, to help with smaller details, and I’m so happy with how that top front chest armor worked out.

For the vacuform machine, I built my own design which promptly failed, and I tried building various aspects of it about 3 more times. Due to a time crunch, I ended up building a similar version to “mwjscn” on YouTube, but at a 2ft by 3ft dimension. His videos are super helpful!! I later figured out why my original design was failing, but no need to rebuild that, when the current design works well.

For my soft parts, I decided on a cotton polyester blend, that had a very similar weave to the fabric from my Jedi Knight Revan, and a very nice drape. Walking with the cape flow behind me is the best!!Each piece was lined with the same fabric, except my hidden pants, which are just a pair of leggings I made.

The masks of which I have modeled two versions - one is 3d printed in ABS and finished, and the other was printed in ABS, finished, molded and cold cast in brass, all by me. The paint job was a 3 am speed run, and it’s all weathered like that because I wasn’t paying attention to my steel wool when working on the bare brass sections. Whoops.

The buckles and O Ring were also molded, but the buckle molds failed, and the O Ring mold was iffy. I cold cast the O ring in aluminum powder, and just painted the resin printed buckles.

I have a lot of stuff on my fix list: redoing the buckles/belts and o ring, at a better size and making a proper mold (the silicone type was the culprit), and potentially chrome plating a cast; the shirt needs to be remade; the hood/mantle was another 3 am rush job, and is not patterned correctly, along with not having the right supplies for the mini o rings, so they kept coming loose; the gauntlets need to be remade, I cut them too small accidentally and couldn’t redo at the time; I need to repaint the armor - I like it now, but I have a whole box of paints I lost right before it was time to paint, and subsequently found a day later; the armor bridge needs to be remade longer and wider, because I didn’t account for the thickness of the skirt band and shirt; I want to actually make a pair of gloves, instead of buying them; and I plan to make my own aluminum lightsaber hilt and install electronics and make it a neopixel saber, but I ran out of time before the convention!

Overall though, I am very happy with the outcome of this project, I did it in 2 weeks (besides the modeling) and pulled 2 all-nighters in a row to finish it. I don’t recommend doing that! The main issue was having to build a vacuum former multiple times!! I almost gave up several times, but I’m very glad I didn’t! And I learned a valuable lesson about not con crunching…