Here is a project I have been trying to finish for over a year and finally took time this week to complete it!
Here's a video of me developing the final model and assembling it if you're interested!
For Halloween this year I am going as Tony Stark (from Iron Man 2). I designed the chest arc reactor screenshots from the movie and 3D printed the parts in Carbon Fiber PLA to make it lighter. To attach the part to the shirt I used two parts and some simple 5/8" screws.
The model can be built WITHOUT any supports. If you do make one please share with us! I know there are plenty of novel ways that this can be made better or tailored for a specific use and would love to see what you do with it.
I used el-wire I purchased from Amazon (here is an affiliate link to what I used https://amzn.to/2NCxtiX I'll get a small fee if you choose to purchase) and used a low-temp hot glue gun to bond it to the surface. To make the screws sit flat on the side facing my chest, I used a chamfer deburring tool.
Protopasta Carbon Fiber PLA
Carbon Fiber PLA is not the easiest material to print with. I've printed with regular PLA with no issues. The key here is to make this as light as possible, so if there is a material like HIPS you can print with that is lighter - go with that if you are going to wear this.
Here is a timelapse of me developing the final model and assembling the costume.