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Cosplay custom falcon wings by ETERESHOP, how we did it

Cosplay custom falcon wings by ETERESHOP, how we did it

In this article we will tell you about how we created Falcon Marvel wings. If you are interested in fantasy or you are a circus performer, or maybe you are going to surprise your friends and family on Halloween with big mechanical wings, we can confidently say that you should read this article.

Contents:

Cosplay marvel falcon wings for Halloween

The client had a desire to create marvel moving falcon wings for Halloween, but none of the companies dared to take on the job.

As soon as ETEREshop heard about this crazy idea of making wings for Halloween, we were immediately interested and thought it would be an interesting experience and brainstorming session for the whole team. The challenge was to create large mechanical Captain America cosplay wings from The Falcon and The Winter Soldier for Halloween.

First of all, we discussed all the nuances and wishes of the client. The client sent a photo of the large mechanical cosplay wings that he likes. He said that he wants moving wings and needs to be done before Halloween. As a result, we had 4 months to pick up materials, create and test mechanical cosplay wings.

See how we created custom cosplay Marvel Falcon Wings:

Marvel's Mechanical Falcon Wings
Marvel's Mechanical Falcon Wings, desired image of the customer

Sketch cosplay of mechanical falcon marvel wings by ETHERESHOP

Our task was not only to develop a new model using the highest quality materials, but also to take into account all the wishes of our customer. After a long discussion, we began to develop the design using Autodesk Fusion 360.

 

Sketch of mechanical wings in CLO
Sketch of mechanical wings of a falcon in CLO

Stage 1 of the mechanical marvel falcon wings cosplay sketch developed in the Fusion 360 program.

large wings sketch
Sketch of the falcon's marvel wings in CLO

Stage 2 sketch cosplay of Falcon wings.

Sketch of Marvel's mechanical wings for adults
Sketch of Marvel's mechanical wings for adults with a shield

Stage 3 of the falcon marvel wings sketch.

Look at how we did cosplay wings sketch in the Fusion 360 program:

creating a sketch of wings
Video how the sketch of mechanical marvel falcon wings cosplay was created in the Fusion 360 program

Design of large falcon wings and selection of materials

The next task for our team was the detailing of the feather, which we solved by gluing several layers of EVA. EVA is a composite polymer material. A modern, environmentally friendly and hygienic material that has found wide application in various areas of life. In order to hide the construction, we decided to fasten the feathers on both sides in the places where the profile was attached to one point. To power and operate the mechanical wings for adults, we decided to use a 12-volt lithium battery.

Modeling of the front big wing for cosplay
Modeling of the front of a large mechanical Falcon Wing Cosplay on the Computer
Modeling of the back of a large mechanical Wing
Modeling of the back of a large mechanical Falcon Wing Cosplay on the Computer

Detailing will be done by glueling the layers.

Detailing wing on a computer
Detailing a large falcon wing on a computer
Detailing wings in the program CLO
Detailing the wings of a falcon for adults on a computer in the program CLO
Mechanism for opening the feathers in the wings
A mechanism for opening feathers in Marvel's mechanical large wings

A square aluminum profile of 2 sizes: (20×20, 15×15) was chosen as the basis for the mechanism, which made it possible to create the most accurate contact of the mechanism.

We decided to use a linear actuator as a driving mechanism.

linear actuator design as a driving mechanism
Design linear actuator as a drive mechanism for large mechanical wings
linear actuator as a drive wings
Linear actuator as a drive mechanism for large mechanical wings

The developers modeled and printed a plastic part to firmly fix the drive. 

plastic part for mounting the drive for wings
Plastic part for mounting the drive for large wings
fixing the drive for large wings
Fixing the drive for large wings

However, after several tests, this fastener broke and it was decided to replace it with a metal plate.

metal fasteners for fixing the drive of huge mechanical wings
Metal fasteners for fixing the drive of huge mechanical wings cosplay

Assembling feathers for falcon marvel wings

The next task for our team was the detailing of the feather, which we solved by gluing several layers of EVA. EVA is a composite polymer material. A modern, environmentally friendly and hygienic material that has found wide application in various areas of life. In order to hide the construction, we decided to fasten the feathers on both sides in the places where the profile was attached to one point.

gluing of feathers for mechanical wings
Video on the assembly of feathers for large falcon wings

The sketch of feathers was transferred to the thermoplastic and cut out for further gluing. The cut 1 mm thik termoplastic turned out to be very flexible, which did not allow to make a rigid structure. We tried to fix this problem by increasing the thickness of the thermoplastic by another millimeter, but it turned out to be too heavy. The material of the feathers had to be changed. Therefore, it was decided to glue the EVA material and reinforce it with a U-shaped profile (6x6x6) by the sides, and the places for fastening the feathers with an aluminum strip. This decision made it possible to significantly reduce the weight, and also gave the necessary rigidity to the entire structure. For primer we used a mixture of liquid nails and water (1:1) and covered EVA with it. Also it was noticed that for a more stable color, you can not tint the places where the paint has peeled off, so feathers needed to be completely covered with color.

Drawing of a feather for wings
Drawing of a pen for cutting from EVA material
Detailed drawing of the pen
Detailed drawing of the pen for further transfer to the material

Gluing EVA

Eva is glued together with the help of COSMO.

Carved feather from EVA material
Carved feather made of EVA material for large cosplay wings

Painting feathers for cosplay mechanical falcon wings

To give an external resemblance to the sketch, some elements of the wings should have been painted. It was decided to try to paint the material. During the painting of the fender parts, it turned out that the paint did not adhere well. Our team continued to study this issue and came to the conclusion that in order for the paint not to peel off, the material needs to be primed.

Painting a pen made of EVA material in blue
Painting a feather made of EVA material in blue to match the wing falcon

Assembling a profile for cosplay falcon wings

The profile was fastened together with a screw-tie. Round profile inserts with a diameter of 10 mm were inserted between the feather and the profile so that the feathers do not interfere with each other folding.

metal material profile
Metal material profile for large wings
assembled metal profile of mechanical wings
Metal profile of mechanical wings assembled by ties

Look at how we assembled the frame for the mechanical falcon marvel wings

Assembling a metal frame for mechanical wings
Video of the frame assembly for large mechanical wings

Making a backpack for falcon mechanical wings

A metal backpack was developed for the convenience of wearing moving cosplay wings.

sketch of a backpack
Sketch of a backpack for storing the mechanism of wings


After drawing the 3D model, the designer transferred the pattern and drawings of the back plate to the metal. Since the wings have a moving mechanism, they need to be controlled. For this, a 3-position button was soldered into the power gap, which allows you to open and close the wings.

Creating a redwing for custom wings and mounting it in a backpack

According to the stylistic feature, the redwing hides in a backpack folded and is an integral part of the wings, but according to the customer’s wishes, it should be unfolded, so it was necessary to figure out how to fix it. It was decided to glue the bolts to the redwing, after which it was necessary to insert grommets in front of these bolts into the back of the backpack, then the redwing was fixed with nuts.

creating mechanical wings
Video about the process of creating mechanical wings

Development of the redwing drawing

We broke the model in Pepakura for further construction of parts.

Drawing of the redwing model
Drawing of the redwing model in the Pepakura program

Designing parts

We transferred the redwing drawing from Pepakura to EVA material.

Cutting EVA material to create a redwing
Cutting EVA material to create a redwing

Gluing redwing parts for custom wings

After receiving the individual parts, they were glued together using COSMO glue.

Gluing redwing parts from EVA material
Gluing redwing parts made of EVA material for a backpack

Painting redwing for cosplay falcon mechanical wings

In order for the paint from the redwig not to fly off, Eva needs to be primed. A mixture of liquid nails and water was used for priming. Then the paint was applied to the redwing.

Redwing for Marvel Falcon Wings
Ready made redwing made of EVA material and painted as in the sketch

Custom Cosplay Marvel Mechanical Falcon Wings

After 4 months of continuous work on creating cosplay mechanical wings, we managed to recreate a character from the TV series The Falcon and the Winter Soldier. With cosplay wings for Halloween, our customer did not go unnoticed and uses them in everyday life when he wants to surprise the audience and attract attention.

If you want to order cosplay wings for an individual order, write to the manager by mail sales@etereshop.com

Video of Marvel's big moving wings
Video ready-made mechanical wings of the Marvel Falcon

See other options of wings by ETEREshop:

Submit an application for Falcon Marvel wings HERE.

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