Samus Aran

This project involved lots and lot of EVA foam, which was all covered with 4 coats of Smooth On 65D, which gave it a hard surface, it was then sanded, filled with wood filler, sanded some more, primer and painted and finally airbrushed. We built a basic spandex unitard which was padded with hip pieces like the reference image, and was a surface to stitch the buckles to to keep the armour in place. After assembling, LEDs were inserted throughout the costume with a battery pack in the chest armour piece in the back. Two cooling fans were inserted in the helmet to keep the cosplayer cool while wearing the costume. Thanks to @tsukuyomi_cosplay and AsperJosh Photography for the photo!

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