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Iron Man Suit with AWS IoT

Overview​

This project combines cosplay craftsmanship with IoT technology to create functional Iron Man suit components. Using 3D printing, ESP32 microcontrollers, and AWS IoT Core, I'm building an interactive Iron Man experience with real-time connectivity and control.

Project Goal​

Build a wearable Iron Man suit with:

  • 3D printed helmet and armor pieces
  • IoT-enabled electronics
  • Real-time cloud connectivity via AWS IoT Core
  • Interactive features and animations

Technologies Used​

  • Hardware: Seeed Studio XIAO ESP32C3, LEDs, sensors, servo motors
  • Manufacturing: Creality 3D Printer
  • Firmware: Arduino C++, MicroPython
  • Cloud: AWS IoT Core, AWS Lambda
  • Communication: MQTT over WiFi

Components Built​

Mark 3 Helmet​

  • 3D printed Iron Man Mark 3 helmet
  • Integrated electronics and lighting
  • Motorized faceplate mechanism
  • IoT connectivity for remote control

Mark 85 Faceplate​

  • Detailed Mark 85 faceplate design
  • Advanced servo-controlled opening/closing mechanism
  • LED eye lighting effects
  • MQTT control via AWS IoT Core

Key Features​

IoT Integration​

  • Real-time control via AWS IoT Core
  • MQTT pub/sub for commands and status
  • Cloud-based state management
  • Mobile app control capabilities

Interactive Electronics​

  • Programmable LED effects
  • Servo-controlled mechanical movements
  • Sensor integration for automatic responses
  • Battery-powered operation

3D Printing Workflow​

  • STL file sourcing and modification
  • Multi-part printing and assembly
  • Post-processing and finishing
  • Electronics integration planning

Technical Highlights​

Microcontroller Choice​

Using Seeed Studio XIAO ESP32C3 for:

  • Compact form factor (fits inside helmet)
  • Built-in WiFi for IoT connectivity
  • Low power consumption
  • Arduino ecosystem compatibility

AWS IoT Architecture​

XIAO ESP32C3 → MQTT → AWS IoT Core → Lambda Functions → Control Commands

Power Management​

  • Rechargeable battery systems
  • Power regulation for different components
  • Sleep modes for extended operation

Community Engagement​

This project was presented at:

  • AWS User Group Wellington
  • Community demonstrations and workshops
  • Conference talks on IoT and maker projects

Build Process​

  1. Design Phase: Select Mark version and source STL files
  2. 3D Printing: Print helmet and armor components
  3. Electronics Planning: Design circuit layouts
  4. Assembly: Integrate electronics with printed parts
  5. Programming: Write firmware for IoT control
  6. Cloud Setup: Configure AWS IoT Core and Lambda
  7. Testing: Validate all features and connectivity

Challenges & Solutions​

Challenge: Space Constraints​

Solution: Using ultra-compact XIAO ESP32C3 modules and careful wire routing

Challenge: Power Distribution​

Solution: Multiple voltage regulators and isolated power domains

Challenge: Mechanical Reliability​

Solution: Iterative design improvements and robust servo mounting

Future Enhancements​

  • Full suit integration (chest piece, gauntlets, boots)
  • Voice control using Alexa or custom voice assistant
  • Augmented reality HUD display
  • Multi-suit fleet management via AWS IoT
  • AI-powered gesture recognition

GitHub Repositories

iron-man-iot

Source code and documentation for Iron Man IoT project (if available)

View on GitHub →

Media​

Check out build progress and demos on my YouTube channel