Tony Stark designed some pretty spectacular armor. So much so that tons (technical term) of cosplayers try to replicate it. The increasing accessibility of 3D-printers is opening a new door. Cosplayer Ryan Brooks has used the technology to create a plastic replica of the Iron Man helmet. Yeah, I think Stark would approve.
Brooks discusses the process for developing the fit and features in a couple of videos. You can definitely see how close the helmet is to the on screen version. The next step is getting a printer that actually prints metal to make it even more realistic.
See videos of the process after the break.