Hello. No one seems to have done anything in this group at all since inception. That honestly sucks, as I was hoping that someone would have put in some time and at least come out with some sketches, or put their thoughts down on paper.
Well I am not one to complain without doing something about the problem. First up is the issue of powered movement. That is the core of Iron Man's super strength. You have 3 real options here. Hydraulic, Stepper Motor, or Servo Motor. I have filtered out hydraulic simply because it is not as easy to work with as the other electrical motors. I found a comparison chart, and a link to it is posted below.
Based on the information it contained, I would say that a stepper motor is the most efficient way to go. It takes more power to run, and generates more heat, but neither of those problems is difficult to deal with. Heat syncs, and a propane/natural gas generator will solve both of those problems readily.
The next problem is the exoskeleton, the armored body of Iron Man. I have looked into materials, and the difficulty in casting them, or machining them. ZA, or Zinc Aluminum alloys seem to be the way to go. They are relatively easy to make, requiring only about 900F to melt them, they cast extremely well, and they make extremely fine detailed castings. When they set up, they have hardness equivalent to that of Cast Iron. They also lend themselves readily to sand casting, mold casting, and to graphite casting.
Alright, I have put my 2 cents in. Lets hear from the rest of you.