Very Simple IronMan Arc Reactor and Helmet




About: I am IT professional, living in Bangalore, India. As new gadgets come out everyday, we indulge in spending significant time and money on these gadgets. And our kids are learning from us, they know how to use...


Now days, it is easy to buy things in India, like I can get IronMan Mask easily in toy shop.. But arc reactor is still not available.

I did read a lot of intructables for it, but could not get silicon molds and resin casting kit around.

The one I am sharing in this intructable is simple and components can be easily found or bought, I am using a semi transparent cap from wife's night cream. It makes things very easy

Step 1: What Do We Need ?

Arc Reactor

  • 01 : Semi transparent cap ( Diameter : 3 inches ), wait for wife to finish though-es expensive night creams
  • 04 : 3mm Blue diffused Leds
  • 01 : 3v Volt coin battery
  • 01 : Battery holder
  • 1 to 2 Mtr : Brown wire; I extracted it from Cat5e cable ( brown pair )
  • Double side Tape
  • Universal PCB
  • 01 : On / off switch
  • Black Chart Paper


  • Big piece of card board / carton box
  • Paper tape
  • Paster of paris
  • Fevicol
  • Acyrlic paint ( Red and Golden)


  • Soldering Iron
  • Paint brush
  • etc

Step 2: Arc Reactor : Prepare Outer Shell

  • Use a metallic pin or paper clip
  • heat it on a candle flame
  • and make holes on the plastic cap as shown
  • Using brown wire( insulated), wind around each hole

Some of the instruction available, uses PVC sheet and lazer cutter, to build circuit like design inside the arc reactor.

Where do I get the lazer cutter ? I do not have one and not cheap to buy one.

Easy solution, I used black chart paper ( Thicker than normal paper). Simply by cutting and pasting on the cap

Step 3: Arc Reactor : Build It

  • Fix a On/off switch on the cap as shown
  • Solder 2 wires
  • now solder 4 leds, battery holder
  • The leds are in parallel
  • Solder the PCB on to the Switch as shown
  • Cover the back using PVC sheet and use tape to keep it in place

Since the battery is just 3V, I have not used any resister

Step 4: Helmet

  • Print the attached
  • Paste the prints on a cardboard and cut them out
  • Use paper tape to make joins as shown
  • Before we paint the helmet, we will coat the helmet by paste of plaster of paris and White Glue
  • Let is dry for 24 hours
  • use a sand paper to smooth the surface
  • Paint the helmet with Red and golden color

I use white glue in the paint as it gives a little glossy finish.

Step 5: Show Off

Take a selfie and update facebook ;)



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    11 Discussions


    3 years ago

    Mine iron man helmet via pep files . how's it?

    1 reply

    4 years ago

    Hey man you should try using pepakura files. This is mine using the files

    15, 5:57 PM.jpg
    3 replies

    Reply 3 years ago

    hello.. I already have files on my pepakura viewer.. my problem is, I dont know how to scale it to fit my head.. please help me.. thanks..


    Reply 3 years ago

    I could find PDF files for mine. for just fine for me


    4 years ago

    That's pretty cool


    4 years ago

    nice work dude. turned out nice. the mask was a bonus. thanks for sharing.

    1 reply