Iron Man costumes have been extremely popular lately and the number one question I am most often asked is "How can I add animatronics to my suit?" My friend Greg wanted to add animatronics to his MkIII fiberglass suit so he asked for my help and for this suit we went all out.
We wanted to add as many functions as seen in the movies as possible, which wasn't easy given that most of those sequences were not done using practical effects. The other issue was how should all of the functions be actuated? After considering several options we used RFID tags in the gloves to trigger the shoulder rocket pods, hip pods, forearm missile, back flaps and helmet. The helmet has wireless control via XBee radios. The boots light up and make sound while walking by using an infrared distance sensor in the boot to trigger the effect.
Here's a video that shows all of the suit functions-
This is certainly not an easy project but if you know your way around an Arduino and can wield a soldering iron this instructable will show you how to do it.
Be sure to click on any picture to get a larger version.
Update: I've also created an animatronics forum where people can go to get help with their costume and prop projects. I get so many messages for specific project help from people that I decided to create a dedicated forum where everyone can get help and share ideas!
Let's get started!