Create Realistic Metal Props for Your Cosplays.

Normally, when making a cosplay with robotic or mechanical parts, the first thing we do is reach for the old reliable silver paint. Whether it's 3D printed or handmade, silver paint always saves the day. But what if we could make pieces that look forged from metal? Below, we'll see a process in which we use real metal to cover cardboard pieces and give them a heavy, metallic finish.

And the best part is, it doesn't require welding.

Although it's a simple process at first, there are some tips which you will see below.

1. Scissors.
2. X-acto.
3. Glue.
4. Tape.
5. 1-2mm Aluminium Sheet
6. Spray paint
7. screws and flat washers

First of all, you should understand that this process will mostly benefit those cosplay props or pieces that are robotic or mechanical. It can also include weapons like swords or axes. Then we have to choose which pieces of our costume can be worked on with this technique.

So I made a sketch of what I wanted to do: a kind of robotic glove. I prepared a concept to guide me along the way.

What will be done is a metal covering; in my case I will use cardboard as the base material, but you can use EVA foam or any other type of material used in cosplays, these being the two main ones.

I will use a sheet of metal 1 to 2 millimeters thick since it is easy to manipulate

The process is very simple, but if you handle the placement of the tabs correctly, the cardboard will adhere to the metal much better. It's your decision whether to use glue to further reinforce the bond; in this case, the tabs are sufficient.

Cut out the shapes you need. Here you can see the two phalanges of the fingers; draw them separately on the cardboard and cut them out, but don't glue them on yet.

After cutting them, transfer their edges to the metal and, once you have the resulting template, add as many parts as you want; it can be a simple or complex finger, this adds more detail in the end.

Cut the resulting pieces with special metal scissors

Pay attention to every detail, as in some cases the folds may be cut incorrectly and ruin the piece.

Make the necessary folds on the piece. First, use an embossing tool along the fold lines, then press down on the edges with your fingers to create straight folds. Mark each part with a pencil and label it to avoid confusion.

Then insert the cardboard piece inside the metal piece and secure it firmly by pressing the tabs so that it remains immobile inside the metal piece.

You've just made one phalange of the hand. Now repeat the process until you've formed all the fingers, and do the same with the pieces for the back of the hand and the palm.

The more pieces you cover with metal, the more detail each piece of your cosplay will have. It's also highly recommended to use screws for these joints.

Each individual piece adds more detail to the final structure

After having many pieces to form the structure of any piece, be it a weapon, a sword or this hand in my case, I recommend leaving internal tabs and putting screws where convenient

For that, use a cutting-point tool to open the holes where the screws will pass through.

Then insert the screw with the eyelet if necessary and tighten with a screwdriver from the other side until it is tight. In some cases where you feel they are not firm enough, use glue to reinforce them.

For pieces with curved shapes, you will need to cut small tabs to fit the metal piece correctly.

Always remember to transfer the template to the metal and then leave at least 1 or 2 cm for the tabs.

Here you can see two pieces covered with metal. These two pieces have volume, so you should cover them while assembling them. Then, reinforce some corners internally with cardboard.

Once you have the finished pieces, whatever they may be, you can apply paint and they will maintain the illusion that they were forged in a metalworking shop. In this case, I used glue, let it dry, and then painted it, finally removing the glue to give that worn effect to the metal piece.

*You can also use sandpaper to give the metal an aged or battle-damaged effect

Finally, you can create simple or super complex pieces depending on what you're looking for and the specific characteristics of each prop in your project.

from a metal shoulder pad for armor, to an ultra-detailed robotic helmet.

Thanks for watching!