Introduction: Iron Man Mask

Iron Man is a fictional character from the Marvel universe, who is pretty famous among people from all age groups.

People love his technology and his suit. This Instructable guides you on how to make an Iron Man helmet from scratch at home.



  • Cardboard Sheets (not more than 0.5 cm thick) if corrugated better.
  • Old Newspapers
  • White sheets of paper
  • Paints: Crimson Red Metallic Gold Metallic Silver (optional)
  • Transparent Tape
  • 12 small rectangular magnets and 2 small round neodymium magnets.
  • Buckram (or you can also use some stiff cloth),
  • Size: 1 meter by 1 meter will be more than enough for all sizes
  • Fine plastic net (5 x 5 cm) 2 safety pins


  • 1 k ohm Resistor (you can even use up to 3k ohm)
  • 7 white led lights (you can use your favorite color)
  • 1 switch
  • 1 9-Volt Battery
  • 1 9-volt battery connector
  • A few connecting wires

Step 2: TOOLS

  • Soldering Iron
  • Solder Wire
  • A ruler
  • A pair of scissors
  • A thin marker pen
  • A pencil
  • and Thick flat brushes


Measure your head diametrically and print out the above template such that the 2 opposite sides match the measurement you have taken as shown. Try to take it 2 cm longer so there is space for padding.

Now print out the template according to your head measurement and paste it on the cardboard sheet using some glue. Cut out the template form the cardboard sheet carefully using craft knife. Cut out the faceplate marked with YELLOW color. Cut out the rest RED part. Now fold along the BLUE lines. Curve the faceplate to fit the rest of the helmet. Your basic structure is ready. You can also add any personal details if you want.



Cut out 4cm in width sheets of Buckram or any other stiff cloth material with length equal to the side of your head measured in step 3.

Use as many sheets as you want.

Now paste these sheets with the help of craft glue onto the sides of the top part of the helmet.

Cover any space between the strips with the help of small segments of the material.

You can even use thin foam for this purpose.


Add magnets on the shown locations so that your faceplate and the helmet can stick properly.

Please make sure that opposite poles of the magnets are facing each other so that they attract and try to keep the same pole configuration everywhere.

Step 6: Adding Strength to the Helmet

Mix equal parts of glue and water in a bowl and tear the newspaper in small pieces.

Now apply the mixture on the faceplate and whole helmet separately and paste newspaper fragments onto it.

After the first coat dries, repeat the above process multiple times to give the required strength to the whole helmet.

During this process cover the helmet entirely inside and outside both.

Do apply extra coating on the hanging flap above the faceplate to make it stiff.

Step 7: Adding Covering to Eyes

Cut the plastic net into 2 rectangles of equal dimensions and paste them on the eyes from behind the faceplate of the helmet as shown in the figure.

Step 8: Adding Electronics

  • Make a pocket on the inner side of the helmet using some cloth to hold the 9V battery
  • Add a 9V battery connector to the upper arm of the faceplate using some glue and stick some neodymium magnets on the connection points.
  • On the upper part of the main helmet just above the place where you have added the magnetized connector add some safety pins or any subsequent material to act as touch points.
  • Stick them either by using some glue or screw them into place using small screws.
  • Adjust them such that they touch every time you stick the faceplate.
  • Now make an array of LED's by soldering them in parallel with each other.
  • Don't forget to add connecting wires on negative and positive terminals of the battery.
  • Now inside the faceplate add a switch and connect it the array of LED's you made.
  • Now stick the array of LED's to the faceplate just above the eye slits using transparent tape.
  • You can also add paper tape to diffuse the light produced by the LED's.
  • If the wires stick out you can glue them using Hot Glue.

Step 9: PAINT

  • First cover the whole outer surface of the helmet with blank white paper pieces using the glue-water mixture used in step 6
  • Paint the faceplate with a metallic gold color
  • Paint the rest with iconic crimson red color
  • You can add any details if you want for example, I have added mark 85 silver on sides
  • You can then outline the details with a pointed marker
  • You can also coat it with clear epoxy resin to give it a more metallic look.


Wear the helmet, turn on the lights and roam the streets or play in your house, perfect for every occasion whether it be Halloween or a house party you'll be recognizable everywhere.

Please give it a try and for any suggestions you can use the comments section.

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