Arc Reactor Power Supply – Iron Man Inspired Battery With Recycled Materials

What if Tony Stark's Arc Reactor existed as a real desktop power source?

This project combines electronics, battery technology, and science-fiction-inspired design to create a functional Arc Reactor Power Supply. While it won't power an Iron Man suit, it can safely provide power for microcontrollers, LEDs, and sensors, or something bigger like my homemade humanoid robot.

The goal was to build something that looks like it came straight from a Marvel movie while also serving a practical purpose. The result is a very simple rechargeable battery-powered power supply enclosed in a custom Arc Reactor housing that powers the systems of my real size humanoid robot.

Many makers have created Arc Reactor props for cosplay and display purposes, but this project focuses on creating a device that actually delivers usable and portable electrical power.

This project was built mostly from recycled and salvaged components that I had available in my workshop. Because of that, it may be difficult to find the exact same parts used in this build.

Rather than following a strict parts list, I encourage makers to adapt the design using whatever materials and components they already have available. The main idea is to reuse parts creatively and understand the underlying principles of the project.

One of the goals of this project is to demonstrate how useful and visually impressive devices can be created from materials that might otherwise end up as waste.

You can watch the full build on my channel: https://youtu.be/1ehf1cjsi5o?si=tLsUanqX9jpO8QLV

Electronics

1. 5x Recycled 18650 lithium-ion battery
2. Toggle Power switch
3. Output connector
4. white or blue LEDs (I used a 5V 3" LED ring circuit and a central 12V LED)
5. 12 V to 5 V DC-DC converter (LM2596)
6. wires
7. 12V intelligent pulse repair charger (To charge the battery pack)

Mechanical Parts

1. 3D printed Arc Reactor parts
2. plastic, acrylic or metal cylinder for housing (Diameter: between 3.5" and 4" Height: 3")
3. Clear acrylic diffuser
4. Small screws
5. Hot glue tube as diffuser

Tools

1. Soldering iron
2. Wire cutters
3. Multimeter
4. Screwdrivers
5. 3D printer
6. drilling machine

The first step is building the Arc Reactor frame, which is the visual centerpiece of the project.

You can download the included files and 3D print the two reactor components inspired by Iron Man's iconic Mark II Arc Reactor design. These parts give the power supply its distinctive futuristic appearance and transform it from a simple electronics project into a display-worthy piece.

After printing the parts, I sanded the surfaces and improve the finish. Once prepared, I painted the reactor with a chrome finish and added gold accents to highlight the details and enhance the overall look.

Feel free to customize the colors and finish to match your own version of the Arc Reactor.

The visual centerpiece of the project is the illuminated reactor core.

To create the main lighting effect, I positioned a 3-inch, 12V LED ring around the 3D-printed top frame. This provided a bright and even source of light while simplifying the wiring. If you don't have access to an LED ring, you can achieve a similar result by arranging individual LEDs in a circle and connecting them with appropriate current-limiting resistors.

To diffuse the light and eliminate visible hotspots, I repurposed a hot glue stick. By carefully forming it into a circular ring and placing it over the LEDs, it acted as an effective diffuser, spreading the light evenly across the reactor face and creating a smooth glow.

For the center light, I installed a 5V LED and reused the diffuser lens from a broken LED spotlight. This helped soften the light and gave the reactor core a brighter focal point, similar to the appearance seen in the Iron Man films.

One of the goals of this project was to reuse materials whenever possible, so many of the lighting components were salvaged from old or damaged electronics. Feel free to experiment with different LEDs, diffusers, and lighting arrangements to achieve the look you prefer.

At this stage, you should already have the characteristic Arc Reactor glow and begin to see the project come to life.

To power the Arc Reactor, I decided to reuse parts that would otherwise have been thrown away. I salvaged several 18650 lithium-ion cells from the battery pack of old broken laptops.

After carefully opening the battery pack, I used a multimeter to measure the voltage of each individual cell. Some of the cells were completely discharged or showed signs of deterioration, so I selected only the five cells that still had healthy voltages and appeared to be in good condition.

I then connected these cells together to create the battery pack used in this project. While this approach helped reduce costs and gave new life to components that would have become electronic waste, it is important to understand that working with salvaged lithium-ion batteries carries risks.

I do not recommend that beginners replicate this method. Recovered cells can have unknown histories, reduced capacity, internal damage, or safety issues that are not immediately visible. Improper handling can result in overheating, fire, or battery failure.

A much safer and more reliable option is to purchase new 18650 cells from a reputable supplier and install them in a proper battery holder. This approach simplifies assembly, improves safety, and makes battery replacement much easier in the future.

Although I chose the recycled route for this build, using new cells and a battery holder is the method I would recommend to anyone building their own version of this project.

One of the biggest challenges of this project was finding a housing that could fit all of the electronics while still maintaining the Arc Reactor appearance.

After searching through my workshop, I found a 3.5-inch plastic cylinder that was almost the perfect size. It provided enough internal space for the battery pack, wiring, switch, converter, and connectors while also matching the dimensions of the 3D-printed Arc Reactor top piece.

Once I was satisfied with the layout, I secured the components inside the housing using a combination of hot glue and small screws. The hot glue helped keep wires and smaller components in place, while screws provided a more secure mounting method for parts that might experience stress during handling.

One of the themes of this project is adapting available materials rather than using a strict parts list. Because of that, I encourage you to find a housing that works with the materials you have access to. The exact enclosure is not critical to the design.

Possible alternatives include:

1. PVC pipe
2. Plastic tubing
3. Metal pipe
4. 3D-printed cylinders
5. Repurposed containers

The most important requirement is that the housing provides enough room for the electronics and can securely support the Arc Reactor faceplate. Don't be afraid to get creative. sometimes the best solutions are the parts already sitting on a shelf in your workshop.

The power system of the Arc Reactor was designed to provide both the visual lighting effects and a usable power output for external devices.

To build the battery pack, I connected five salvaged lithium-ion cells in series, creating a battery pack with a nominal voltage of approximately 12V. This voltage is used throughout the reactor and is also available at the output connector.

The outer LED ring is a 12V LED assembly, so it is connected directly to the battery pack. However, the center LED requires only 5V to operate safely. To power it, I added a DC-DC step-down (LM2596 buck) converter between the battery pack and the center LED. The converter reduces the battery voltage to a stable 5V output while maintaining good efficiency.

To allow the reactor to be completely shut down, I installed a toggle kill switch on one of the battery terminals. When the switch is turned off, power to both the lighting system and the output connector is disconnected, preventing battery drain during storage.

Since this reactor was designed as a power source for my humanoid robot, I added a connector at the reactor output that matches the robot's power input. but you can easily replace this connector with any type that best suits your own project.

For charging, I used a 12V intelligent pulse repair charger. Because the reactor's output is connected directly to the battery pack, charging is simple: whenever the batteries need recharging, I connect the charger to the reactor's output connector. This eliminates the need for a separate charging port and keeps the design clean and compact.

Before connecting any external devices, always verify the output voltage with a multimeter and ensure your battery pack is wired correctly.

Building this Arc Reactor Power Supply was a fun way to combine engineering, electronics, and creativity into a single project.

It looks like a movie prop, but it's also a functional portable power source that can power real devices. Future upgrades could include wireless charging, battery level monitoring, USB-C power delivery. You can watch the full build on my Youtube Channel: FUNCTIONAL ARC REACTOR FOR MY HUMANOID ROBOT

Before attempting this project, it is important to understand that lithium-ion batteries can be dangerous if handled improperly.

Always:

1. Inspect batteries for physical damage before use.
2. Verify voltage and polarity with a multimeter.
3. Avoid short circuits.
4. Use appropriate charging equipment.
5. Keep batteries away from excessive heat and flammable materials.
6. Monitor batteries during charging whenever possible.
7. Dispose of damaged or worn-out cells properly according to local regulations.

If you are new to working with lithium-ion batteries, I strongly recommend using new cells from a reputable supplier and installing them in a proper battery holder or battery management system (BMS) rather than building a pack from salvaged cells.

This project was created for educational and experimental purposes. Build responsibly, follow appropriate safety practices, and proceed at your own risk. Thanks👍