Cosplay design and fabrication
Sergeant Calhoun Cosplay
I designed and built this Sergeant Calhoun cosplay from Wreck-It Ralph for my wife to wear at Salt Lake FanX and again for Halloween. I drafted all of the patterns specifically for the build, constructing most of the armor from foam and adding lights to the shoulder straps. Smaller dimensional details were 3D printed, and we sewed a simple corset foundation to support the fitted armored silhouette.
Project details
- Production
- Salt Lake FanX and Halloween
- Designed by
- Bryan Johnson
- Materials
- Foam armor, 3D-printed components, Integrated lights, Fabric
- Techniques
- Pattern drafting, Foam fabrication, 3D printing, Costume lighting, Corset sewing, Hand finishing
- Notes
- All armor patterns were drafted specifically for the wearer. The costume combines a sewn corset foundation with lightweight foam armor and illuminated shoulder-strap details.