Close
0%
0%

Elysium Max Exoskeleton

Exoskeleton suit replica from the movie Elysium in Autodesk Inventor, 3D printed and investment cast out of Aluminum

Similar projects worth following
I wanted to create several exoskeletons for band members of my next (industrial metal) music project. I like the "hacked together" look of the exoskeleton worn in Elysium (2013) by Max Da Costa, so I chose to replicate that one.

See the original movie suit in action.

I designed and printed all of the parts, machined pistons on a metal lathe, and sewed a harness. Now I am working on casting all of the plastic parts out of Aluminum using the investment casting process.

The printable STLs are available here and on GitHub. See the assembly instructions if you want to put together one of your own. 

I often post videos of the metal casting process. Here's the latest one, shot with a virtual reality camera:

Standard Tesselated Geometry - 45.85 MB - 02/11/2017 at 18:56

Download

Standard Tesselated Geometry - 222.93 kB - 02/11/2017 at 18:53

Download

Standard Tesselated Geometry - 225.86 kB - 02/11/2017 at 18:53

Download

Standard Tesselated Geometry - 220.59 kB - 02/11/2017 at 18:53

Download

Standard Tesselated Geometry - 161.51 kB - 02/11/2017 at 18:53

Download

View all 142 files

View all 138 components

View all 41 project logs

View all 38 instructions

Enjoy this project?

Share

Discussions

Dan DWRobotics wrote 07/29/2017 at 22:22 point

Very interesting project. I really enjoyed that film. Interesting to see that you are casting your own parts from aluminium. The actual casting part is really difficult, I know because I have tried it. Since you are putting in so much effort into making it from metal, are you not tempted to make some of mechanisms function like a real robotic exoskeleton? With assistive actuation and motors? great project, will follow with interest.

  Are you sure? yes | no

Liam Mason wrote 07/12/2017 at 14:16 point

What grade Aluminium did you cast it from? I'm intending to make my own exoskeleton design. However, I'm not sure on the best choice of Aluminium from the extensive variety available.

  Are you sure? yes | no

Valeriy Novytskyy wrote 07/12/2017 at 14:42 point

I am using this right here (closest to 356 alloy):

http://www.ebay.com/itm/ALUMINUM-INGOTS-43-lbs-26-to-30-ingots-Casting-alloy/182166261652

The quality is a lot better than you would expect - I originally bought this as practice stock, but then realized it's actually top-shelf casting stock sold cheaply :) I get as-cast surfaces that are literally polished with no further work required.

Lastly, I did consult with two mechanical engineers here at the hackerspace (one who works at Intel and one who works in a local machine shop), and they both pointed me to 356.

  Are you sure? yes | no

Liam Mason wrote 07/12/2017 at 14:47 point

Thank you for the help :)

  Are you sure? yes | no

Valeriy Novytskyy wrote 07/12/2017 at 19:20 point

You are casting, right? The alloy is completely different for CNC/machining, 6061.

See https://www.metalsupermarkets.com/7-things-consider-choosing-aluminum-grade/

  Are you sure? yes | no

Liam Mason wrote 07/13/2017 at 00:45 point

Ah right. No I haven't decided yet on whether I would cast or CNC/machine it out, while CNC is much more expensive I don't really have the appropriate tools/location to cast. 

  Are you sure? yes | no

Liam Mason wrote 07/13/2017 at 01:12 point

I've also been looking around for months but can't seem to find those type of pistons/hydraulics used in the joins of your exoskeleton. Is there a specific name or site I've missed? Or did you get those custom manufactured? 

  Are you sure? yes | no

Valeriy Novytskyy wrote 07/13/2017 at 03:53 point

I manufactured the pistons, see page 6 of my RPF build thread:

https://www.therpf.com/showthread.php?t=212832&page=6

...through middle of page 7:

https://www.therpf.com/showthread.php?t=212832&page=7

I don't regret learning how to use a metal lathe, but in retrospect this was the wrong decision for the project. Lathe was $500, tube stock I ordered was around $500 as well, and I spent 2.5 months, about 45 hours per week, machining until late night and coming home each day looking like a coal miner. Then I spent another $100 taking them to a painting plant not to mention I had to wake up in the middle of the night to make it back in time for work.

Knowing what I know now, I would say either low-tech them if you are going for appearance and use a convenient size of pipe (2 diff. diameters cut & inserted into each other), or post for help on a CAD forum to learn how to make drawings and submit them to a machine shop (and have them do high-detail matte/gloss indoor electro-coating). Price will likely be the same for machine shop as doing it yourself, BUT you get to spend all that time hanging out with friends instead of machining and crying :)

  Are you sure? yes | no

joe wrote 04/04/2017 at 15:10 point

So with these files being online.   I want to ask first.  Is this design an open source design.  I think it is amazing looking and would like to make one myself.  I  don't think i can come close to getting this level of detail.  Also this suit looks amazing!

  Are you sure? yes | no

Valeriy Novytskyy wrote 04/08/2017 at 15:22 point

Prop replicas are never completely open source, since Sony owns the right to the movie and all props (you are always a voicemail away from Cease and Desist). However, all the files have been created from scratch and a few parts differ from on-screen appearance (thus it's not an exact copy) so as long as nobody's crazy enough to sell it they will likely let it slide.

  Are you sure? yes | no

ConsultingJoe.com wrote 02/26/2017 at 14:50 point

what 3D printer did you use

  Are you sure? yes | no

Similar Projects

Does this project spark your interest?

Become a member to follow this project and never miss any updates