Instructables
Recently i have been re working my first iron man Arc reactor to stream line the production time etc. i decided to take a look at making the Arc reactor from the second film.  so this is how i went about making my Iron man 2 arc reactor.
 
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Step 1: Tools and materials.

Tools:

- sand paper
- files
- small saw and coping saw (fret saw)
       ~these tools are if you dont have access to a laser cutter
-knife, craft knife, scalpel (something to cut thin materials with)
-ruler.

Materials:

- 3mm acrylic (any colour as it will be painted)
- 2mm acrylic (any colour but you will need some clear, i used all clear for all of it to make it easier)
- thin blue plastic. the type that they make document folders from.
- liquid solvent glue
- Spray paint. plastic primer, silver paint, clear coat.

Step 2: Planning.

I sketched out a little plan to help me work out how the layers of the arc would work.

once i had an idea of how many layers i needed i could work out how thick and what materials to make the arc from.

i worked out i could make the arc out of 6 layers and if they were 2mm each it would give the arc a nice slim line depth of 12mm. (although nearer the end of the build i realised i needed another 2mm layer on the rear to aid with the mounting in the stand)

after the sketching i drew up some plans in Illustrator using some source photos i got from goolge.

Step 3: Cutting and pre assembly

Picture of Cutting and pre assembly
cut the plans out on a laser cutter, all the main parts were cut from 2mm extruded acrylic. (the blue colour is the protective plastic.)

you can cut these parts by hand if you dont have access to a laser cutter, just be careful on the delicate parts.


Glue the parts together in groups of two. leaving out the parts that would be clear.

layer 1 and 2, layer 3 and 4 and 5 and 6.
findmarc7 months ago

Great job! The EL panels have a lighted effect and can be cut down to a custom size. See image. I have found a good source for the panels here www.el-w.com and
here www.etsy.com/shop/lightkraft They were the best prices I've
found in the US.

blue panel.jpg
backwards lamb (author)  findmarc7 months ago
Yes I know. That's why I used it.
007619Ali8 months ago

What Kind Of LEDs Did You Use??

backwards lamb (author)  007619Ali8 months ago
​no LEDs in this it's an Electro luminescent sheet.
michhross10 months ago

By any chance do you have the files posted on here so I can use them to cut out the shapes? :)

Sethaulton1 year ago
Whats the radius of the whole arc reactor?
i never laser cutted anything.. so what i will have to say if i want ones like you??? please help me out..
thanks for the reply, im also wondering how thick is the arc reactor? is it thin enough to fin under a t shirt? im considering using another deisgn for an arc with less detail than yours but is only 12 mm thick
im pretty sure if you use 2mm plastic for the layers it will be 12mm thick.

this is made in three sets of two layers each, the layers are 2mm, so its 3 groups of 4mm . 3x4=12 :)
hi, first i have to say this is one of the best arc reactors i've seen
my question is what color spray paint you used for the arc reactor
thanks
Erm I'm not sure or the paint name (it was automotive spray paint from halfords in the uk.) but its just a bright metallic silver paint.
Man, this was by far my favorite of Tony's Arc Reactor, and it is great to brag to my friends :P
Rob_2831 year ago
what i mean with the back of the reactor / the stand are these things....
backwards lamb (author)  Rob_2831 year ago
I did it just how I said I did in step 5. I looked at photos found on a google search and drew the. Up on illustrator and cut them out on a laser cutter.
Rob_2831 year ago
Why 3mm acrylic? You say you made all the parts out of the 2mm...
And how to make the stand? the back of the reactor?
backwards lamb (author)  Rob_2831 year ago
Parts of the base were 3mm but you can use 2mm
What do you mean "and how to make the stand? The back of the reactor?" ?

The stand was made by looking at the source photos and copying the design as well as I could.

trebory61 year ago
What's the best place to buy the acrylic sheets? I've been looking everywhere, and can't seem to find where they sell these. :/
backwards lamb (author)  trebory61 year ago
Well it depends where you are. I'm in the uk so I get mine from : www.plasticstockist.com but I wouldn't know where to get it anywhere else.
1597531 year ago
Nice project, I don't have access to a lase cutting machine , so y made every piece on my own with my dremmel based on your schematics, here's a picture of it , thanks !
487600_10200176213041171_2050663732_n.jpg
backwards lamb (author)  1597531 year ago
That's great work. It looks really great. Thank you for sharing your picture. :)
Please could you attach the Laser cutting files??
looop451 year ago
I love this!