Spartan Armor (Metro Exodus)

Project Summary:
- Designed and fabricated a wearable Spartan Armor set from Metro Exodus, emphasizing durability, modular design, and realistic weathering techniques for a post-apocalyptic aesthetic.
Design and Fabrication Steps:
[1] Chest Armor Construction:
- Built the chest plate in two layers for depth:
(a) Inner plate made from 1/8-inch ABS, cut with a jigsaw, edges smoothed with a WEN detailing sander, and thermoformed for a contoured fit.
(b) Outer plate made from 1/16-inch ABS, shaped and glued to the inner plate using ABS cement.
- Added decorative tabs from 1/16-inch ABS, glued in place for layered detailing.
- Reinforced the assembly with 1/4-inch button head rivets for durability.
[2] Shoulder and Abdomen Plates:
- Fabricated shoulder plates from 1/8-inch ABS, thermoformed to match the curvature of the shoulders.
- Sewed black Cordura nylon covers for the shoulder plates, adding MOLLE webbing made from 1-inch black nylon straps for a tactical look.
- Created the abdomen plate from thermoformed 1/8-inch ABS, covered with coyote brown Cordura nylon for a rugged finish.
- Attached decorative straps and D-rings using 1-inch coyote brown nylon webbing for added functionality and detail.
[3] Strapping and Assembly:
- Connected armor pieces with 1-inch elastic straps, Velcro, and nylon webbing for adjustable, secure wear.
- Attached plates and shoulder armor to a Matrix Level-1 Plate Carrier base, ensuring modularity and comfort.
[4] Painting and Weathering:
- Applied a base coat of Rustoleum Matte Black spray paint to all ABS components.
- Dry-brushed edges with metallic gunmetal acrylic paint to simulate wear.
- Added a weathering wash with black and brown acrylic paint to enhance depth and create a worn, battle-tested look.
Challenges:
- Ensuring modularity for ease of wear and transport without compromising structural integrity.
- Achieving a realistic weathered effect on large armor components.
- Balancing durability with lightweight design for extended use.
Results:
- Delivered a highly detailed, wearable Spartan Armor replica with modular components for easy assembly and storage.
- Successfully replicated the rugged, post-apocalyptic aesthetic of the Metro Exodus design.
Engineering Skills Demonstrated:
- Thermoforming: Shaped ABS plastic for contoured chest, shoulder, and abdomen plates.
- Textile Integration: Combined Cordura nylon and MOLLE webbing for tactical realism.
- Painting and Weathering: Applied dry brushing and acrylic washes to replicate a post-apocalyptic look.
- Modular Assembly: Used Velcro, elastic, and rivets for adjustable, removable components.