Fallout Deathclaw cosplay- build process!

Finished product first! I've been working on this cosplay for my partner for the last 4 months. I put the finishing touches on it yesterday and we got pics taken today!

I started by sculpting the head on NomadSculpt on my ipad. I made a shell of it for printing.

Head 3D printed in PLA. I had to print out on multiple pieces done my print bed is small.

Painting the horns before attaching them.

Horns and teeth painted, and vision mesh and eyes installed. It has yellow LEDs in the eyes.

I use masking tape over it to make the pattern for the skin!

Marking where I want each color and where I want the scales to be.

I used the making tape to trace pieces onto the fleece then sewed them together. I glued it on the head then airbrushed it.

Feet time! Took an old pair of shoes and cut some rubber coated foam mats to be the bases. I made a foam wedge under the heels of the shoes to give my partner more height.

I used 1/2 inch upholstery foam to make the shape of the feet up to the heel. The claws I also sculpted on my ipad and 3D printed in TPU for durability.

Using masking tape again to make a pattern for the feet skin.

Feet skin sewn and ready to be glued

Feet skin glued using spray adhesive and hot glue

Feet airbrushed! They have a zipper on top to zip onto the body

Hands time! I made a glove out of a lightweight and breathable material, techno knit neoprene. I cut some upholstery foam pieces to build up the finger shapes.

Roughly glued on

Shaped down with scissors

Looking good

With 3D printed TPU claws added

More making tape for the hand pattern

Hands sewn and glued on

And airbrushed!

Next up is the tail. I did a spine out of EVA foam, then built up blocks of 1 inch upholstery foam in sections so it would wag while my partner walks.

TPU printed spikes attached to the top

Skin sewn, glued, and airbrushed!

Now it's time for the body. I made an undersuit of of techno knit neoprene since it's breathable. I added hollow sections of foam hot glued onto it. I had to build up foam layers.

Zipped on feet and tail and glued on all the spikes

Looking good!

Final work on the under of the body

You guessed it, making tape time! Making the pattern for the body skin.

Got legs cut and sewn first

The rest of the body cut, sewn, and glued on.

And airbrushing! This step took a long time

Sorry for blurry Pic here, more airbrushing

And done! He looks very monstrous

I do need to extend the flap covering the zipper on the legs, I'll do that before the convention

Back view looks great

I'm very happy with him :D

Rawr!

Movement looks great, I especially love how well the tail moves.
We will be bringing him to FanExpo Denver in a few weeks! If you see us, please say hi, I made some custom bottlecaps to give out. I'm working on a vault suit for myself to go with this guy.