Category: Projects

Posts relating to ongoing cosplay projects

Emergency Medical Hologram – LFCC/DT 2023

So I decided somewhat last minute to go along to the London Film and Comic Con in Spring 2023. With Destination Trek later in the year in mind, I figured I could make a Trek costume which I could refine and reuse for that convention. I’ve had a bit of experience making Deep Space Nine/Voyager style uniforms for Destination Star Trek 2019, and had found the process straightforward enough that I reckoned I could make a teal medical/science version within the time available.

The method I used for the uniform involved sourcing a long sleeve black top to serve as a base and a teal t-shirt from which I would cut the shoulders. I already had a metal voyager-style pin badge as well, and the EMH doesn’t have a rank so no need for rank pips.

Of course an EMH outside of sickbay requires a Mobile Emitter, and thanks to the wonders of the internet and 3D printing it took me minutes to find an STL file and a few hours to print and paint it.

In the past I have wanted and been unable to find a good enough Tricorder, only ever finding a small one that didn’t really work for cosplay purposes. Once again my 3D printer offered a solution, though the tricorder model was pretty much the largest thing my small printer could manage. This is the model I chose to print, as it was broken down into small enough components.

The print overall took several hours over several days. Fortunately I was still working from home so could supervise the printer over longer prints. Alas I didn’t have time to paint it before LFCC, so had to go with it unpainted as a prop.

EMH beaming down to Kensington

I found the metal pin badge a bit heavy and dragging on the uniform, so I decided one of the refinements would be to print a lighter magnetic voyager combadge, and I also intended to find or make a 3D printed hypospray to go with the tricorder (after I had painted it).

Portal 63: Making the Spear

The first (and arguably less important) task for the Portal 63 cosplay was obtaining a spear of the right design. I also had the additional requirement, beyond the spear being foam (or similar soft material) that it would have to be collapsible. This was both to make transporting the spear easier, but also because I would be wearing the costume throughout the day, including when attending panels and stage events. Having learned from previous years about being considerate towards those sat behind me, I would need to be able to partially disassemble the spear when sat down.

The best solution by far, given the collapsible requirement and the specific design, was to make the spear myself. This would count as the “new skill” for this costume as I’ve never tried to make a cosplay weapon prop before, let alone one as long as a spear. Fortunately a good friend of mine had some advice, and I have an ample supply of those most useful materials: 3mm foam and hot glue.

For the shaft of the spear I ventured to a (not very) local hardware store to acquire a 2m length of black plastic piping, along with three push-fit connectors and two end caps. I went for the 32mm diameter because I wanted the added thickness to hopefully make the final product more solid. The spear head isn’t a very wide design, so I figured there wouldn’t be too much of a torque on the joints to require more permanent securing methods.

Pipe, pre-cut, and joiners.

I bought a pipe cutter to cut the pipe in half, and reduce the overall length as necessary. Then I glued the joiner sections with hot glue, one to each end of the lower pipe. The upper joiner would be the base of the spearhead, which I wanted to be detachable for portability reasons. I drew a cardboard template for the spearhead, and used that to cut out sections of 3mm foam to make the head and handle sections. A lot of hot gluing later:

Spear made with foam additions, pre-painting

Painting the parts was relatively straightforward, using a base coat of black and top coats of brown/silver acrylic paint.

Painted

Now I just had to make the rest of the costume…

Ensign Boimler – Destination Trek 2023

The first planned costume for Destination Trek 2023, Friday 18th, was Boimler from Lower Decks. As this was intended to be a lower effort mostly-bought costume, there isn’t a lot to really say beyond sourcing and ordering the uniform and coloured hair wax. However there were a couple of parts which I did make.

Magnetic Starfleet Rank Pips Set

These were not made specifically for the Boimler cosplay, I had the idea to create a set of magnetic rank pips after my experience with some pin-badge style ones I had bought for previous conventions. By far the biggest issue, especially when applying them myself, was getting the spacing and alignment right. Any rank beyond lieutenant was basically impossible, so with a 3D printer I figured I could design a magnetic strip and a set of pips that would make aligning them a lot easier.

First I had to find a source for the size and dimensions of Starfleet rank pips, as well as their spacing. Fortunately a google image search yielded this:

Pip dimensions

This would make the design very straightforward, as simple shapes like cylinders are very easy to create and combine in Blender. One concern I had was the magnets I intended to use might have been strong enough so close to each other to make gluing them difficult, but it turned out this wasn’t an issue. The intent was to create a strip of five magnets, four “full” pips and one “junior” pip. This would allow any rank from ensign to captain possible, including lieutenant junior grade and lieutenant commander.

Printing the strip was relatively straightforward, but I had to print the pips twice. The first print had support structures which were very difficult to remove, and with the pips being only 8mm across I tried printing without supports. There was some material drooping, but not too much that I couldn’t remove it. I then used superglue to attach the magnets one at a time (to avoid the attraction between magnets dislodging them before the glue set.) Then they just needed painting, a base coat of black and overcoat of gold.

Printed, magnetised and painted.

If you want to print a set of these pips yourself, I uploaded the STL files to Thingiverse.

Lower Decks Combadge

Modelling the Lower-Decks style combadge involved importing a 2D image of the communicator into blender to use as a template for creating a 3D version:

Combadge Image
3D Model

I also designed and printed a magnetic clip to hold the Combadge to a uniform. Printing and painting took a few hours.

Combadge printed and painted, along with magnetic clip

If you want to print your own Lower Decks style combadge, I also uploaded the STLs to Thingiverse.

Destination Trek 2023 Projects

August 2023 is the Destination Trek convention, and three days of Star Trek means three days of cosplays! My last outing to Destination Star Trek 2021 in London was incredibly successful with my Q cosplay, and in all honesty I don’t expect to replicate the sheer volume of positive feedback and photo requests I got back then.

But I try not to dwell in the past, even a successful cosplay has its time and then I have to move on to something new. Because there are three cosplay opportunities I tend to try and focus my efforts on a “main” cosplay for the convention, with other cosplays either being low-effort buy-and-wear affairs or an economical use of efforts for preceding conventions (like LFCC or MCM) that I can then re-use (or improve on) for Destination Trek.

This year my three project plans are:

Ensign Boimler from Lower Decks – This will be my lower-effort affair, and part of a possible group cosplay. This will involve buying and combining elements rather than making anything from scratch.

Portal 63 from Next Generation Episode “The Last Outpost” – This will be the main project, making basically everything from scratch.

Emergency Medical Hologram from Voyager – This is my re-use project, which I originally made for LFCC Spring 2023 (with the intent to re-use it) however I have some plans to add to it prior to August.

DMos: MCM Comic Con October 2022

MCM Comic Con came around at the end of October 2022. Unfortunately time ran out to work on the lower half of the planned costume, but I had enough made to work with. I ordered a pair of maroon trousers that were intended to be the base for the lower portion of the costume, but would be close to the final colour to work without modification.

DMos final costume

The bald-white-hair wig was the closest I could find to Dungeon Master, and I didn’t think I could make one. I used a 4xAA battery pack in a pouch secured around the waist and a power lead routed down the left arm to the gauntlet.

DMos at MCM

DMos: Creating the Upper Body

With the gauntlets made, the remainder of the costume was next. My original plan was to do a full-body costume, with trousers and boot-covers. However with looming time constraints I had to prioritise, which meant focusing on the upper body first. The upper body would be broken down into three main pieces: The sleeves, to be attached to a plain black sweater; the vest to be worn over the sleeves (and attached if time allowed) and the collar to be worn over the vest.

The Sleeves

Measuring the black sweater as a template, I marked the rough location of my elbows while wearing the sweatshirt in order to estimate where on the pattern to place the elbow pad, and to work the design out around there. The design would involve sections of metallic red spandex as “plates” of armour separated by strips of gold spandex sewn underneath.

The Vest

With limited knowledge of sewing patterns, I used the sweater again as a guide, combined with rough measurements of myself to get the sizing right. Knowing the limitations of my experience, I added some margin to these measurements, but in the end the vest still ended up very tight to wear. It involved two pieces, a front and back, with the red spandex as an underlayer and strips of gold spandex for a bottom border and vertical “seams” across the front.

Even with the walking foot sewing machine head (which was such a worthwhile purchase when dealing with the spandex) over longer seams and a greater number of thread breaks the alignment between the two base layers drifted noticeably, but not beyond the excess material I had left around the template. The rear section was similar to the first, lacking the V-shaped extension at the bottom and only featuring the lower horizontal border of gold.

The Collar

I created the collar using a darker metallic red fabric I had managed to find online. To create the gold “pips” I cut pieces of 3mm foam into circles and sewed a layer of gold spandex around them.

Gold collar pips being created

The collar was made from two pieces, with an outer border of gold spandex and eight coins/pips sewed on.

The Necklace

An additional component was the Dungeon Master’s pendant or necklace. Lacking the time to design/print a more 3D version, I resorted to trusty old 3mm foam and hot glue to create a makeshift version.

Pieces of necklace prior to gluing and painting

DMos: The Right-hand Gauntlet

Creating the corresponding right-hand gauntlet for DMos was, predictably, a much easier and quicker process. With no circuit or inner layer and the templates for the outer design already crafted, the only real task was modifying the design to remove the dice mounts. This would be achieved by replacing the knuckle-mounted dice with a simple “bar” of metallic red spandex, and replacing the larger oval d20 mount on the back of the hand with a flat oval piece of gold spandex.

Base black cotton layer with first gold spandex layer

To help give the gold oval its shape, I used 3mm foam to cut an insert around which the material would be sewed. As with the other gauntlet, a base of black cotton was used, with an initial layer of gold spandex.

Right gauntlet pieces

As with the other gauntlet, the red and gold spandex had to be layered to achieve the desired design. Unlike the other gauntlet the outer layer was attached directly to the inner glove.

Right gauntlet assembled prior to attaching to glove

With the pieces of the gauntlet assembled, they just needed attaching to the inner glove in the same manner as before. The gauntlets were by far the more intricate aspects of the overall cosplay, but the remainder of the costume would be considerably larger and, with a temperamental thread all to happy to snap in the sewing machine, considerably more annoying to put together.

DMos: The Gauntlet Outer Layer

With the lighting circuit and dice mounts successfully attached to the base layer, the final stage of creating the Infinite dGauntlet was to create the outer wrapping layer. For the design I took primary inspiration from the Nano-gauntlet in Avengers: Endgame, as this was closest to the Iron Man red/gold colour scheme that would fit best with Dungeon Master.

I used the same template I had created for the base layer, but added around 1cm of depth in order to add space for the circuit board and wiring, and added cut-out sections through which the dice mounts would protrude. Using the same black cotton fabric as a base, I used metallic red and gold spandex to build up the required design, using metallic thread which did not play well with the sewing machine at all.

Gauntlet wrist/palm outer layer pieces prior to assembly

The fingers were similarly designed, essentially creating short tubes of fabric to be attached to a simple black glove that would be sewn inside the base layer.

Base layer and components of outer layer prior to final assembly
Fingers sewn and attached to the glove

All that was left was to slip the outer layer wrist/palm section over the top and hand-sew the seams.

Completed gauntlet awaiting dice

The dice were then secured in their mounts using superglue to complete the Gauntlet.

Completed Gauntlet, illuminated
On a glove stand

DMos: Mounting the Lighting Circuit

With the lighting circuit, dice mounts and base layer complete, it was time to bring them together. The first thing to do was to superglue the d4 into its mount, to avoid having to glue the two halves together later. Then I attached each mount to the relevant pad using superglue.

Attaching the circuit itself involved inserting the LEDs and sewing their cables in place. The tactile switches were sewn into their respective pockets, then the wires were fixed in position by sewing loops of thread.

I threaded the power socket through a button hole so it could be accessed from the inside of the wrap-around.

Mounted lighting circuit in action

DMos: The Gauntlet Base Layer

Gloves can be complicated, and my clothing design and manufacturing skills are limited. I had to work within what I could feasibly achieve, and having made a variation on an infinity gauntlet before (don’t ask) I decided to go with the approach I took last time: Use a standard glove to sew fingers onto, then sew that glove inside a wrap-around for the palm, which would essentially be a tube with an extra bit on the side for the thumb.

The wrap-around would consist of two layers:

  • An inner base layer, onto which the dice mounts would be glued and the circuit would be mounted (with hand sewing)
  • An outer layer, consisting of the actual visual design, with holes through which the mounts would protrude.

My approach to coming up with a pattern is very geometric, essentially approximate with a boxy design and hope the fabric’s tendency to curve will round it out. It’s also easier to think of a polyhedral net of flat faces rather than a more complex curved topology. The first step was, of course, to get measurements.

When in doubt, trace around it

Pretty simple, trace around my left hand and use a ruler to roughly measure the notable lengths. Mark off where my knuckles and wrist were (roughly). Add a bit for ease of putting on/taking off, then create cardboard templates.

I also intended to add patches for the dice mounts, so I could be more exact when eventually attaching them.

I transferred the templates to black cotton using chalk, which is a rather inaccurate method. I later got some wax pencils which worked a lot better.

With external edges hemmed

The first version was a little too tight to put on and take off, so a revised layer was made. I also decided to go with a single “bar” across the knuckles, with dividers sewn on top, instead of the individual stone pads I had originally used. This saved on complexity, and also supported the edges better which were a little wider than the finished glove layer.

To the underside (where the palm will be) I added six miniature “pockets” for the tactile switches, each approximately 12x12x6mm in size.

With the glove inserted

I had actually made this prior to fabricating the circuit, so once I had a finalised size for the circuit board the last thing to do prior to assembly was to sew on a “sleeve” into which the circuit board would be secured.

With PCB sleeve

Simply a piece of fabric slightly larger than the board, with a notch sewn halfway across the top. Three of the LEDs would feed through either side, and the notch would prevent the board itself sliding through. Once inserted, I planned to sew a second notch in the bottom edge to hold the circuit board in place.

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