Instructables
After seeing Iron Man in the theater I knew I had to recreate Tony Starks Arc Reactor. Specifically I wanted the RT1 that Pepper Potts had displayed in the glass case for Tony. The "Proof That Tony Stark Has A Heart" Arc Reactor. Below is a comparison of the Arc seen in the movie and the one I built.
 
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Step 1: Blueprinting

Picture of Blueprinting
The first step was to draw up blueprints of the proposed Arc. The blueprints would need to show every piece that would be used to create the Arc. I spent weeks going over screen caps from the movie, using various angles to determine the dimensions of each part. I also used several images of the actual Arc that had been displayed at Comic-Con. All my blueprints were created in Illustrator.

Step 2: Parts, parts, parts.

After I had the blueprints completed I began creating the individual parts that would make up the Arc. For this project, I primarily be laser-engraved and cut most of the parts out of varying thickness of plexiglass. In addition, I cast the central ring in clear urethane with a "Coke-bottle" green tint added. The base was cut on a CNC out of MDF.

Step 3: Rear Cage

One of the hardest parts to recreate was the cage for the Arc. The only reference I had at the time were reflections of the back seen on the display case. The cage ended up being built from 29 laser-cut plexi-glass pieces. The cage was also very important, because it would hold all of the LED lighting.

Step 4: Assembly

Picture of Assembly
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At this point, all the major sub-assemblies were complete and I began fitting them together. The first real indication of what the finished Arc would look like.

Step 6: LED Testing

Picture of LED Testing
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LED05.jpg
LED06.jpg
Testing the LED's for the Arc to make sure they have the right look.
could you put the blueprint's up on to the instructable please. thanks
eljeko7 months ago

great job!

andytangtsk8 months ago
Hi that's really cool, I've been a fan of Iron man and would love to build my own arc reactor, would it be possible for you to send the files to me via email? My email is andytangtsk@gmail.com, thanks!

Very nicely done! At first I wasn't sure which was which. :)

RISICO9611 months ago
Hello
Really awesome work
Is it possible you can send me blueprint drawings with all measurements please.
I plan on drawing them up and laser cutting these parts and make one of my own.
Hopefully :)

please send and really great work
This one especially gave me motivation to make one.

Please send to risico96@gmail.com
Thanks
cjacob31 year ago
Where did u get part? Can u email me thort10@hotmail.com
EdisonGuo1 year ago
How did u get the materials? U brought them or made them? If u brought them,where to buy?
This is awesome! Can you leave a list of materials that you need to make it.
misko131 year ago
The best arc reactor replica ever!!
batmanfan1 year ago
please give a list of materials
Can I order the materialsfor the cage? I lack materials and support here. please reply :(
*materials for
mblazquez2 years ago
Do you have a list of materials???
spiker5462 years ago
can i buy the parts from you as a kit and i assemble it myself?
So cool!!!
Please post a file with all the pieces....Please :-D
aicerg1232 years ago
Awesome job! How thick is it?
cerealfreak2 years ago
Excellent job, one the best instructables I have ever seen. I would ask the same question, that has been asked above have you considered selling these as a completed item or a build it yourself your kit? And not just the finished display model, but a removable one that could be used for costume usage?
Honus3 years ago
Fantastic replica!
reddevved3 years ago
You should sell pre-painted kits or fully assembled ones. I think it would be easier to recreate these because the prototype is always the hardest to make. I would make it myself but no way to make the pieces.
monsterlego3 years ago
Awesome!
Awesome! Just like in the movie! I love the outcome!