Units are millimeters.
Many parts cannot fit on desktop printer beds and should be sliced in halves or quarters in your 3D printing software (such as the software offered with MakerBots).
All parts were polished using 3 grades of sand paper and 10 layers of spray-and-polish using Tamya Fine Modeling Primer.
Pistons were machined separately to achieve a better appearance and more resistance to fracture due to heavy stresses.
The chest piece can be rigged with two fans, and many exoskeleton bones include cavities for lighting using LEDs and batteries.
Exoskeleton spread out to 8 feet on a table.
Forearm with articulated fingers. Not screen accurate, but more detailed than the movie suit.
The whole upper arm/forearm/hand assembly starting from the shoulder blade
Another angle on the arm.
Some parts of the upper body on a manikin.
Upper body with machined pistons in place.
The mounting harness made using thick coast thread, elastic belts, and punches.
Preview of the hand parts when mounted using belts.
The other side of the hand.
Pistons machined on a Harbor Freight mini-lathe.
Piston assembly after machining. One of the shaft caps hasn't been cut from the stock aluminum bar.
Polished parts using Tamya primer, after 10 coats. Each part takes about 2 weeks to polish.
The whole exoframe fits neatly in a box.
This project was designed in Autodesk Inventor using prop auction photographs from eBay and high-res screen captures from the movie. See the short presentation on how the files were designed.