Batman Costume (The Dark Knight Rises)




Here is a quick tutorial on how to make a batman costume. I made this for the Dark Knight Rises midnight premiere. The costume is finished and no WIP pictures were taken. But I will try to describe the process of making the pieces. I hope you all enjoy.


Step 1: Chest

The first piece of the suit that I made was the chest piece. I used an old Under Armour long-sleeve shirt as the base then used foam flooring and craft foam to build up the chest. I used the dark knight suit as a reference but added my own spin on the design. I spray painted the while thing in flat black(three coats, and then one gloss).The foam is attached to the Under Armour with lots of hot glue. After some trial and error I realized that the suit was too tight. So I cut a slit in the back of the shirt and added Velcro to secure the two sides together. Other pieces of Velcro were attached to the shoulders and elbows to connect other pieces of amor. 

Step 2: Pants

The next part of the suit that I created was the pants. These were loose-fitting, stretchable, Under Armour Pants. The armor pieces were foam flooring pieces painted black and then hot glued onto the pants. I had to custom make the pieces of armor to fit my leg length and width. I used the Dark Knight suit as a reference. The chest piece shirt is tucked into the pants, and the armor is draped over the lip of the pants. The utility belt is used to hold the chest armor and pants in place.

Step 3: Cape

The Cape was the easiest piece to make. I used an old black tablecloth, cut scallops on the bottom, and then adjusted clip for around the neck.

Step 4: Cowl and Belt

The Cowl I bought online for about $25, the Belt was $8. They are both Dark Knight Rises Style. I altered the belt from Velcro to a clip for easier wearing and use.

Step 5: Gloves and Gauntlets

The Gloves are just mechanic's gloves that I bought for $8. The gauntlets were Made of craft foam, Velcro and Nylon webbing. The design of the gauntlets really depend on the look that you are going for. 

Step 6: Shoulders

The shoulders were a unique challenge to design and build. They had to work on 3-axis and be thin and durable.I used the craft foam for the upper parts and the foam flooring for the bottom. I attached them to the shoulders on the chest with Velcro. There was also Nylon webbing added on the bottom to attach to the arms.

Step 7: Boots

These are boots I bought for $20 at Walmart they look really good with the rest of the suit.

Step 8: Full Suit Pictures

Here a some final pictures of me in the full suit. Here is a link to a YouTube video of me in the suit at the midnight premier.

Step 9: Blueprints

Here are templates for the suit I made. These are the ones i used to make multiple pieces for the legs, chest, and arms. I can't make a PDF file of the armor, but i will send scale pictures. Also I will attach the reference photos I used for the project.



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    21 Discussions

    Jav Ahmed

    3 years ago

    I enjoyed this tutorial. I'm currently in the process of making my own Dark Knight suit and will rely on this tutorial heavily. Thank you for posting.


    3 years ago

    Tbh, this costume looks really bad! Don't EVER use the textured side of the floor mats!


    3 years ago

    you should've sculpted the cowl


    5 years ago

    This sucks... Jk. Dude. This. Is. Awesome. Maybe one of the best batman costumes on instrucables. Good work.


    5 years ago on Step 4

    This tutorial is fantastic, thank you!! Just one quick question. Is this the Dark Knight Rises Rubies cowl? It looks great and I am looking to buy the same one. How do you like it? Pros and cons? Thanks!

    2 replies

    Reply 5 years ago on Step 4

    No its not a Rubies Cowl. I bought it on ebay. I'm not really sure the manufacturer.

    That came together really well! Awesome job! Do you have an estimate of how much it cost to put together a suit like this?

    1 reply

    With the pieces that you have to make, about $50. But the Mask, Belt, Boots and Gloves about $60. Total about $110. But it could be made cheaper with variations of the bought items.