Skip to content

Week 15 System Integration

🔧 System Integration Week — Final Project: Iron Man Gauntlet

💡 What’s the Idea?

Image

This project is my real-world tribute to the Iron Man gauntlet — a wearable, interactive glove that simulates a “repulsor blast” through controlled gas ignition, LED lighting, and servo-based motion. But this isn’t just about replicating a sci-fi prop. It’s about integrating digital fabrication, mechanical design, and electronics into a compact, cinematic, and functional system.

The final gauntlet includes moving parts, reactive lighting, a custom soundless “blast” effect, and a body-mounted system that makes it all possible — all while looking nothing like a regular 3D print.

⚙️ How It Works

The gauntlet system is divided into three major subsystems:

  1. Glove (User Interface + Output Mechanism)

  2. Gesture control through a flex sensor

  3. A NeoPixel ring for repulsor lighting
  4. A servo mechanism that retracts the blast nozzle after firing

  5. Lightweight and designed to fit snugly, hiding electronics underneath armor panels

  6. Chest Piece (Brains of the Operation)

  7. Hosts the main microcontroller (ESP32-S3 or RP2040)

  8. Reads flex sensor input
  9. Controls the timing of gas release and ignition via piezo spark

  10. Tracks the system's state to ensure safety between blasts

  11. Reservoir (Gas Delivery System)

  12. Contains a motor-actuated gas canister

  13. Fills a transparent tube with gas for approx. 15 seconds (timing under testing)
  14. Gas travels via the tube to the forearm nozzle, where it is ignited

🔩 What’s Going Inside? (Mechanics + Electronics)

Electronics List:

  • Microcontroller: ESP32-S3 / RP2040 (decision depends on pin availability and memory)
  • Flex Sensor – for gesture detection
  • NeoPixel Ring – for reactive lighting
  • Piezo Igniter – to ignite gas
  • Servo Motor – to retract the nozzle post-blast
  • DC Motor – to push gas canister
  • Custom PCB – compact circuit routing for glove and chest
  • MOSFETs & Voltage Regulators – for safe power management
  • Good old powerbank – power supply
  • Clear PVC Tubing – gas flow

Mechanical Components:

  • 3D Printed Gauntlet Fairings – modeled in Fusion 360 / Blender
  • Mounting Frame (hidden) – supports electronics and ensures stability
  • Laser-cut Acrylic Stand – for display
  • Vinyl-cut Custom Liveries – Iron Man inspired, personal touch
  • Surface Finish: Sanded + Primed + Mica-Coated for a realistic metallic look

🧩 Final Shape & Form

The final form of the glove takes inspiration from Iron Man MK 2/3 designs — a balance of sleek lines and exposed tech. The goal is not cosplay but believability — it should look like it could exist. The glove fits snugly over the hand and wrist, hiding the servo and LED systems. The chest piece is worn with straps and is visibly functional. Tubing is visible, but cleanly routed.

Image Gas filling mechanism. Image Final glove rough sketch

🌟 What Makes It Different?

  • Not Just a Prop: It integrates actual ignition, motion, and gesture response — not just lights.
  • Compact PCB & Wire Management: Designed to fit inside the glove — no exposed breadboards or dangling wires.
  • Aesthetic Finish: No “3D print lines” — sanding, priming, and mica metallic coating elevate it from a hobbyist look to a polished prototype.
  • Integrated Display & Stand: It’s a wearable device that transforms into a showpiece with its own laser-cut stand.

🔥 Why Am I Building This?

This glove is something my 12-year-old self dreamed of. Iron Man was my first Marvel movie and it sparked a lifelong curiosity for how things work — mechanics, robotics, control systems. Fab Academy gave me the space, tools, and skills to finally make that dream tangible.

More than nostalgia, it’s a systems integration challenge — combining electronics, mechanics, aesthetics, and safety. It's a love letter to making.

Project Timeline

Week Milestone
March 1–15 Brainstormed system layout, sketched multiple gauntlet design options
March 15–30 Started creating CAD models using Fusion 360 and Blender, studied reference builds from YouTube cosplayers and makers
April 1–15 Prototyped electronics on breadboard (flex sensor + NeoPixel + servo), experimented with layout feasibility
April 16–30 Sketched reservoir system and nozzle geometry, simulated gas flow
May 1–10 Assembled a working blasting contraption, started work on final electronics schematic
May 11–20 Custom PCB designing and routed to fit small enclosures, integration points mapped for all subsystems
May 21–31 Began making 3D printing gauntlet fairings and internal mounts on CAD
Tested piezo igniter safely
Made final changes to CAD for fitment and housing
June 1–3 Full system integration: glove + chest + reservoir mechanism and working finalised
Debugging logic, safety interlocks, and gas ignition timing
June 6-7 Surface finishing: Sanding, priming, and applying mica metallic paint to final 3D prints
June 7–8 Vinyl-cut graphics and livery application
Laser-cutting and assembling the display stand
June 9 Shoot final photos and video, polish documentation and site update
June 10 🎤 Final Presentation Day 🎉 — Project showcase & demonstration

Checkout my Final Project page here

Packaging

🧳 1. Physical Packaging (if you’re showcasing or handing over the glove)

📦 Box Design

  • Material: Use laser-cut MDF or cardboard with etched designs. Make it modular or flat-pack for Fab-style replication.
  • Aesthetic: Stark yet premium. Think matte black with gold/silver accents or raw cardboard with etched circuitry.
  • Opening Experience: Add a dramatic magnetic flap or puzzle-style lock — a nod to Tony Stark’s lab tech.

🔖 Inside the Box

  • Foam/3D printed insert to hold the glove.
  • A QR code card linking to your documentation, GitHub repo, and assembly instructions.

  • Mini booklet or folded poster:

  • Page 1: Why this project matters to you

  • Page 2: Key tech used (ESP32, sensors, NeoPixel ring, servo, etc.)
  • Page 3: How to use it
  • Page 4: How to fab it yourself
  • Back cover: “Dedicated to my 12-year-old self.”

💻 2. Digital Packaging (for documentation & GitHub)

🗂 GitHub Repository

Organized, clean, and clone-friendly:

  • /docs – project PDF + images
  • /hardware – STL, DXF, PCB files
  • /code – Arduino sketches
  • /media – Final demo video, photos, gifs

Include:

  • README.md with a compelling project story, features, and step-by-step fab guide.
  • License (MIT or CERN Open Hardware) to encourage ethical remixing.
  • Credits section.

🌐 Fab Academy Website

  • Create a dedicated final project page with:

  • Final video at the top

  • A long scroll format with sections: Concept → Design → Fabrication → Electronics → Testing → Final Demo → Reflections → Downloads
  • Anchor links for easy navigation
  • Embed GitHub links and iframe for downloadable files

📲 3. Social Media Packaging (for Instagram/Behance/LinkedIn)

  • Start with: “12 years ago, I watched Iron Man. This is what it led to…”
  • Process clips: 3D print, electronics, gesture testing, final spark.

  • Include captions like:

  • “Laser-cut frame to hold electronics.”

  • “Gesture control with flex sensors.”
  • “Propane pulse ignition… yes, I went there.”

📊 LinkedIn Post

  • Reflect on your learning: technical skills, challenges, emotional journey.
  • Mention it’s open source & fabbable.
  • Tag your mentors, Fab Lab, and use hashtags: #FabAcademy #IronManGauntlet #OpenSourceHardware