3D Printed Cosplay Props

Project Overview

Combining my engineering background with my creative interests, I design and create detailed cosplay props using 3D printing technology. One of my notable projects is the Zeraora tail from Pokémon, which showcases my ability to translate digital designs into functional physical objects.

Design Process

• Research & Reference Gathering: Collected reference images from multiple angles, studied the character's movement and physics, and determined scale and proportions
• 3D Modeling: Created base geometry in CAD software (SOLIDWORKS), added details and textures, and ensured printability with proper wall thickness
• Slicing & Printing: Segmented model into printable parts, configured print settings for strength and detail, and printed each segment
• Assembly & Finishing: Removed support structures, joined segments with adhesives, and created a mounting system for wearability

Technical Challenges

Creating the Zeraora tail presented several technical challenges, including designing for both aesthetics and structural integrity. The tail needed to be lightweight enough to wear comfortably while maintaining the distinctive shape and appearance of the character. I used PLA filament for its rigidity and bright yellow color, which was perfect for this Pokémon character.

Skills Applied

This project demonstrates my proficiency in CAD design, 3D printing technology, and problem-solving. It also showcases my ability to apply engineering principles to creative projects, bridging the gap between technical knowledge and artistic expression.