Basically, we know someone that does IronMan for events and parties, along with others that do Spiderman, and so on.
But the suit he has is somewhat failing - the original electronics failed a long time ago, and the reworks (no idea who did) also failed.
So this is at least third, or more, refit for this, but we have taken it on with some serious dedication I think.
The helmet
The helmet has a servo, to lift the visor, and LEDs for the eyes. We actually replaced the electronics on this twice - initially a simple LED controller, and then a more custom board.
The eyes are now WS2812 LED strips. so way more flexible, even if normally just static cyan.
One of the challenges was the current spikes from the servo - it killed LEDs. Big capacitors is the main fix for this.
The suit
The suit was also a challenge, and really, the stuff in there was a mess. Again, two stages, firstly a simple LED controller for the "arc reactor", but now gutting it all and replacing with custom controller handling multiple LED strips, and speakers.
The previous electronics had several primary cells, a rechargeable battery, and speakers and LEDs. But the speakers never worked properly apparently.
The new build takes a lot less space, is rechargeable, and lasts all day.
The gloves
These were especially challenging. The helmet and suit could accommodate a decent USB battery pack. But the glove are too small, so needed a design that could handle a small LiPo, and charging.
The previous electronics were a simple LED torch fitting and 9V primary cell. This was bulky, and just "lit up".
The new design is a rechargeable LiPo, and 88 RGB LED rings with diffuser, button, and repulsor effect.
Overall
The end result is nothing short of as complete revamp.
Less space taken in helmet, gloves, and suit. Rechargeable batteries in all, all lasting 8 hours. BLE linking so sound effects link to repulsor in gloves and helmet sounds.
At this stage there is concern the LEDs for the arc reactor and gloves may be too bright, and the speakers too loud, both of which can easily be adjusted.
Speakers
One of my concerns was the speakers, and I found these were the best. I tried 5 different types.
From PiHut, and really good.
They are glued inside the suit but sound awesome.
My son should have a video on it all soon.
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