Case Studies
The Technology Behind Iron Man 2: 3D Printing and the Future of Film
On May 7th, Robert Downey, Jr. will once again transform into the technologically advanced superhero Iron Man, thanks to his character’s engineering prowess. The plot line parallels the production of the film, also made possible by cutting-edge technology: the latest advances in rapid prototyping, often called 3D printing.
Using a 3D printer by innovation leader Objet Geometries, the film’s production company Legacy Effects created the iconic Iron Man suit, as well as the one worn by arch nemesis Whiplash. This body armor is in fact “print-to-wear” – comprised of pieces that came directly out of a 3D printer, simply finished with paint. Plus it’s specially designed to be durable and comfortable for the actors, who engage in grueling fight scenes while wearing the gear.
Technology That Fits Like a Glove
Robert Downey, Jr. for one is grateful for the technology. He remembers filming for the original Iron Man, which took place before Legacy Effects had an Objet system. The star was in constant discomfort due to the gloves he had to wear as part of the superhero suit. They were extremely tight and made it difficult for him to maneuver. For the sequel, the production company scanned Robert’s hands and used the 3D printer to specially create flexible gloves no thicker than a dime. He was thrilled with the change and happy to work in them for hours.
The 3D Craze, in the Theaters and Behind the Scenes
According to Jason Lopes, systems engineer at Legacy Effects, 3D printing is not yet common in movie-making but is likely to become so, especially as live action flicks make more of a come-back. He says, “in the land of CG, all you need is a computer, but real stunt work calls for endless, identical, often customized props. Thanks to Objet, these are available at the touch of a button.”
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Fender
“I calculated the cost of outsourcing prototypes for one year, and then the cost of bringing it in house. Even after factoring in the cost of the equipment and materials as well as staff time, I still concluded that we could significantly reduce our costs by doing it ourselves.”
Shawn Greene,Senior Industrial Designer, Fender
Arch Day Design
“With our Objet30, we have cut prototype iteration cycles from three days to just three hours, depending on the part design.”
Tom Weisel,President, Arch Day Design
Peltor
“In many cases we can decrease the design iteration from weeks to days compared to buying prototypes outside the company.”
Henric Hansson,Mechanical Designer