Original Designed AI Robot Couple
Construction Documented Video:
https://youtube.com/shorts/qZPNxgfaWns?feature=shared
ADAM-1.2 & EVE-1.0 — Original 3D-Printed Robot Costumes
I created the original concept, designed, digitally sculpted, and built both of these fully wearable robot costumes myself.
The armor was primarily 3D printed in black PLA, then hand-finished and painted white. I used flexible PLA in areas such as the arms and legs to improve comfort and mobility while maintaining the appearance of mechanical armor.
Custom Visor Fabrication
One of the biggest challenges was creating the tinted helmet visor. I started with a 3D-printed PLA master, created a flexible mold, and cast a solid plaster buck. After sanding and smoothing the buck, I vacuum-formed clear plastic over it and dyed the finished visor to achieve its dark, translucent appearance.
I assembled my vacuum former using purchased components and parts I fabricated myself, including the sliding frame mechanism and heating-element housing.
Female Robot Face Mask
For the female robot, I repurposed an older costume mask of my own design because I liked its shape. I reinforced the center with clay and used it as a buck to vacuum-form a new, lightweight plastic face mask.
Electronics and Lighting
I integrated custom lighting systems, including illuminated eyes, addressable LEDs, and a programmable controller built around an Adafruit Pro Trinket microcontroller and rechargeable power system.
The audio system includes a helmet-mounted microphone connected to a forearm-mounted voice changer and a rechargeable amplified speaker.
Cooling and Wearability
Both costumes have two large cooling fans installed inside the chest armor, directing airflow upward toward the neck and face. I also installed two smaller fans inside the helmet for additional ventilation.
My goal was to create two original robotic characters that look convincing in person while remaining comfortable and functional enough to walk, interact, and dance in.
The accompanying video documents the design and construction process, while the photographs show both completed costumes being worn at Halloween events.
Thank you for considering my entry!