How to Make an Iron Man Arc Reactor

Feb 2012

A long time in the making but I'm finally pleased to announce that this arc has

be superseded by a newer design which I'm calling the MkII. The MkII features

laser cut parts from a metallic coloured acrylic and avoid copious hours of bending

and cutting small pieces of wire. These are available as kits of full arcs from my

website.

http://sites.google.com/site/msraynsford/ironmanarcreactors

(http://sites.google.com/site/msraynsford/ironmanarcreactors)

(http://cdn.instructables.com/FGB/ILCX/GYE878H4/FGBILCXGYE878H4.LARGE.jpg)

(http://cdn.instructables.com/FIZ/MVXG/FGTT1OHA/FIZMVXGFGTT1OHA.LARGE.jpg)

(http://cdn.instructables.com/FRZ/4AS8/FGTT1OIM/FRZ4AS8FGTT1OIM.LARGE.jpg)

(http://cdn.instructables.com/FIQ/S892/GYEUBF5B/FIQS892GYEUBF5B.LARGE.jpg)

(http://cdn.instructables.com/FKE/J5DR/FGTT1OIQ/FKEJ5DRFGTT1OIQ.LARGE.jpg)

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May 2010

I've updated this arc reactor design based on the recently released sequel. This

newer instructable features better tips on how to make the fiddly parts and an

easier to build design.

http://www.instructables.com/id/Iron-Man-MkV-Arc-Reactor/

(http://www.instructables.com/id/Iron-Man-MkV-Arc-Reactor/)

The Mk1 arc reactor is now available in kit format. So if you ever wanted to make

your own but couldn't make the parts yourself, now you can buy a kit containing all

the parts, instructions and shaped polymorph.

http://sites.google.com/site/msraynsford/ironmanarcreactors

(http://sites.google.com/site/msraynsford/ironmanarcreactors)

Iron Man Arc Reactor

This instructable is one of two parts detailing how to build an arc reactor and an

iron man mask. Both work together but are written as seperate instructables for

clarity. This part is for the Arc Reactor the Iron Man Mask can be found here:

http://www.instructables.com/id/How-to-make-an-Iron-Man-Mask/

(http://www.instructables.com/id/How-to-make-an-Iron-Man-Mask/)

My costume was built for a fancy dress party but it is so cool I'm thinking about

wearing it else where.

First I needed something to copy, I work best when I'm copying someone elses

ideas so I used the following screen shot of Tony Stark in Iron man as a basis for

my arc reactor. As you can see it has 10 well defined sections and a glowing

centre. I'm also going to use the sleeveless T-shirt and I attempted to grow my own

facial hair in time for the party.

I'm rather pleased at my attempt to make the arc reactor and very happy with the

segments of light that eminate from it. I'd also like to pay respects to the other arc

light reactor on instructables, imagine my horror as the weekly round up arrives in

my inbox only find out that I had been beaten to the write up for the same project.

Update - September 2010

Halloween is coming rounnd again and yes I'm still making them so order now in

time for halloween.

"Will you make me one of these?"

I finally got round to making myself a webpage about these and all of my other

projects, it's still a work in progress but I think it covers the basics for now.

http://msraynsford.googlepages.com/start

(http://msraynsford.googlepages.com/start)

"I live in X where can I buy Polymorph From?"

I get this question a lot, sadly I don't live in x so my insight is never very helpful.

Google is your friend as always but if that fails or you don't feel you can create a

mould to shape the polymorph contact me and I will happily sell you some

polymorph and/or a shaped disk.

Step 1: The materials

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(http://cdn.instructables.com/F1V/WR4B/GYE878IX/F1VWR4BGYE878IX.LARGE.jpg)

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Arc Reactor (/id/Arc-

Reactor-1/)

by Gordon Gekko

(/member/Gordon Gekko/)

You, as Tony Stark, as

Iron Man (/id/You-as-

Tony-Stark-as-Iron-Man-A-

Costume/)

by Jamo_GPiCs Of My ARC

REACTOR.......very easy to

make...........!!! (/id/PiCs-Of-

My-ARC-REACTORvery-

easy-to-make/)The 15-dollar, 15-minute

Arc Reactor. (/id/Super-

easyquickcheap-and-

effective-Tony-Stark-Ir/)

by JustinBrownBuild an Arc Reactor with

Basic Tools and Skills

(/id/Build-an-Arc-Reactor-

with-Basic-Tools-and-

Skills/)

I wanted to make something a bit more substantial for this project and I

remembered I had some suitable plastic in my cupboard. This is the key

compenent for the project. This stuff is called polymorph and can be bought from

places such as Ebay. It's a thermal plastic that melts around 60 degrees C and it

becomes something resembling plastacine. From there it is simple to mold it into the

desired shapes.

The next thing we will need is a light source. I wanted the whole thing to be quite

thin when it was finished and sat on my chest so I opted for some surface mount

white LEDs. Surface mount LED's have a very wide viewing angle and being white

they produce quite a lot of light so they are perfect for this application. I bought

mine from Rapid Electronics, I would plug them with a link but they charged me

more for P&P on the LED's than the LED's cost, so I'm not going to. These LED's

are in a PLCC 2 package which means they are still large enough to be soldered

by hand.

You may also want some surface mount resistors to go with those LEDs. I used the

amazing program at http://LEDCalc.com/ (http://LEDCalc.com/) to work out exactly

which values I need. As I am running these LED's from a 9V battery and wanted

20mA of current to flow throw them. They suggested how exactly they should be

wired and what values I needed (incidently I have stolen the circuit diagram from

them too). For my LED's I required 5x 180 Ohm resistors and 1x 330Ohm resistor.

I mounted the LED's on a peice of plywood, anything will do as you are glueing the

surface mount components down for ease of soldering. A 9V battery and battery

clip are providing the power for the system. These can be bought from any

electrical store as required.

Finally you'll need some wire for the detailed decoration. Wire coathangers could

(http://cdn.instructables.com/F53/MLZX/FGTT1OK4/F53MLZXFGTT1OK4.LARGE.jpg)

(http://cdn.instructables.com/FIN/TE7X/FGTT1OKW/FINTE7XFGTT1OKW.LARGE.jpg)

be used but I used tin copper wire of 22 AWG gauge. There is nothin special about

the wire, it's just hard finding something chunky enough for the job.

Step 2: Wiring of the LED's

Some assembly is required for the LED's. I took my round piece of wood that I was

using to mount the LEDS on and I started to glue the LED's in the desired places.

The circuit from LEDCalc suggested I used 5x 2 LED's and 1 single LED in parallel.

This ties in well with the arc reactor so I had the single LED in the middle and the

pairs arranged around the edges.

As you can see from picture I made two rings of wire around the edges, the outer

wire is 9V and the inner wire is 0V. This ring has the added advantage of providing

an secondary route for the power should something go dramatically wrong in

construction.

The power wires are passed through the back plate through a small hole, this will

allow me to power the LED's when they are encased in the plastic.

Step 3: Making the plastic shape

(http://cdn.instructables.com/F8H/CNRW/FGTT1OH2/F8HCNRWFGTT1OH2.LARGE.jpg)

(http://cdn.instructables.com/FIN/TE7X/FGTT1OKW/FINTE7XFGTT1OKW.LARGE.jpg)

(http://cdn.instructables.com/FTI/MMUJ/FJX8VOL2/FTIMMUJFJX8VOL2.LARGE.jpg)

This is the key stage of the make. The polymorph plastic behaves like plastacine

when it is heated to temperature. This allows it to be pressed into a mold and form

the desired shape. As always I wish I had more photos of the stages involved but I

dont and it's too late to go back (let this be a lesson for budding instructable writers)

The mold is formed using balsa wood again on a more solid plywood base. The

outer circle was cut out of balsa to be the required depth of the arc reactor.

Thinner strips of balse were used as relief pieces and provide the detail in the

plastic (These are roughly the same depth as the wire I used)

(http://cdn.instructables.com/FI0/35E2/FGTT1OGX/FI035E2FGTT1OGX.LARGE.jpg)

(http://cdn.instructables.com/FJT/CVSY/FGTT1OGW/FJTCVSYFGTT1OGW.LARGE.jpg)

(http://cdn.instructables.com/F58/RVPT/G8VV3YGY/F58RVPTG8VV3YGY.LARGE.jpg)

(http://cdn.instructables.com/FTW/0J2D/FGTT1OGV/FTW0J2DFGTT1OGV.LARGE.jpg)

I heated the plastic using water from the kettle, once ready it becomes transparent

and maleable. Care was taken to make sure it was pushed right into the mold to

reach all the corners of the mold. Once fully pushed into the mold the LED disc was

then pushed into the back of the plastic. The plastic pushes slightly around the disc

which holds it in place. The disk must be alligned with the slots in the mold so that

each LED is directly under a raised piece of plastic. (There are no photos of this

because it was all done with some haste)

The final picture shows the plastic once it has been removed from the mold. You

can clearly see the raised sections of plastic and the gaps that are due to be filled

with wire. Under each bump there is an LED, the plastic adds to the diffusion of

each LED and really adds to the overall effect.

Step 4: Adding the details

The final step of the Arc reactor is to add the wire details. Holes were drilled in the

plastic to hold the wire around the edge of the device. Each piece of wire was bent

into a C shape, it was then hooked into a hole on the edge of the plastic and again

into the holes in the centre (see photo). This was enough to secure them in place.

Finally four wire rings were shaped to go around the centre of the reactor. These

are held in with PVA wood glue, although any clear drying glue should do the job

just as well.

As you can see from the third photo the device lights up very well and looks really

good, now onto the final stage to bring it all together.

(http://cdn.instructables.com/FEQ/7AGJ/FGTT1OGU/FEQ7AGJFGTT1OGU.LARGE.jpg)

(http://cdn.instructables.com/FE8/8MQQ/FGTT1OGS/FE88MQQFGTT1OGS.LARGE.jpg)

(http://cdn.instructables.com/FKE/J5DR/FGTT1OIQ/FKEJ5DRFGTT1OIQ.LARGE.jpg)

Make Comment

5 months ago Reply (CN5O75DHJKBK2GI)

Step 5: Bringing it together

As the previous stage finished the arc reactor this final stage is about bringing it all

together in a costume. I brought a sleeveless T-Shirt from the local store for a few

pounds. I carefully sewed a pocket on the inside of the shirt to hold the reactor, this

proved to be a very good idea due to the number of people that wanted me to take it

out and show them during the evening. The wires from the reactor run down the T

shirt and into my back trouser pocket.

After a weeks worth of effort I officially had nearly zero facial hair so I ended up

padding it out with some black shoe polish. I'm particularly proud of the whole

chubby Tony Stark thing I had going on but then this photo was taken at the wrong

end of the evening after quite a lot of good food and drink, normally I'm only half as

fat.

I hope you find this useful and encouraging for your own projects. I hope to add a

plan with some dimensions to this instructable in the future which will help anyone

trying to replicate my attempts.

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jcarey8 (/member/jcarey8/) says:

(http://cdn.instructables.com/FFQ/ESDI/FGTT1OGQ/FFQESDIFGTT1OGQ.LARGE.jpg)

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(/member/sequret96/)1 year ago Reply (CI7TJX4H2WEY0X6)

with all due respect. I agree with you for the most part but you cant look at the movie

as a factual point.. i know you said its fictional but, the detail of your comment mademe think that you have given this a lot of thought, well planed thought.. but i wanna say

this.. the arc is not that far away as you think, of course the actual " movie Arc reactor"is.. but its not impossible to make one.. the focal point would have to be the "cycle"

cycle per minute.. once you create a power source or at least an idea of what kind of

power source you want and can use.. then concentrate on the power cycling so it canbe self sustained.

in closing i would like to say thank you majidkhan536 for shearing your thoughtsbecause i can tell the intelligence in your Analise.. it was awesome.

johnaobrien (/member/johnaobrien/) says:

Just wanted to thank you for the instructable. I plan on making one of these with mygrandson next week. You have made it easily understandable and it looks simple to

build. I live in the states and so I had to purchase my plastic from sparkfun. I got theresistors from radio shack (they do not have flat ones in the store). Everything should

be here next week and we are putting the mold together this week. Thanks a bunch

for the great instructable.

majidkhan536 (/member/majidkhan536/) says:

Stark seems to use Palladium isotope from his missiles as the reactor's fuel. Once

the reaction starts, the energy harnessed is enourmous at 3 GJ/s or equivalent to 3GW. (That's more than twice energy required for time-travelling (which needed only

1.21 GW of power) in Back to the Future films).

This power can be used to power up his suit for a long time for his enhanced reactor,

not the first one.

To make this extremely efficient power supply, I believe we can. And I believe it ispossible. But I think that it can be done only in a few hundred years.

The movie is purely fictional and I believe that the writer are just fantasizing about theperfect energy source. (Dreams mostly become true eventually). If we are living in

19th century, people won't believe you if you can send sound wave and picturesaccross the globe. Now, it's possible. So what makes an arc reactor impossible?

It can be done. But not in recent time.

taufiqismail6 (/member/taufiqismail6/) in reply to majidkhan536

but is it possible if the reactor power

source being replaced by a carbattery?

Alex Jalland (/member/Alex+Jalland/) says:

what does a nine volt battery look like or what is its symbol?

pipsqueakboy (/member/pipsqueakboy/) in reply to Alex Jalland

Its the rectangular one.

Alex Jalland (/member/Alex+Jalland/) in reply to pipsqueakboy

thanks

sequret96 (/member/sequret96/) says:

http://www.youtube.com/watch?v=afsn71yqTP0 heres mine

How to make an Iron Man Arc Reactor by msraynsford (/member/msraynsford/) (/contest/letitglow/)

+ Collection

Download (/id/How-to-make-an-Iron-Man-Arc-Reactor/?download=pdf) 5 Steps

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monsterlego (/member/monsterlego/) says:

(http://cdn.instructables.com/F8W/8EWS/GZLW4E76/F8W8EWSGZLW4E76.LARGE.jpg)

Alex Jalland (/member/Alex+Jalland/) says:

what colour LED did you use?

piratekitten (/member/piratekitten/) says:

check out the stark reactor on this chick.

(http://cdn.instructables.com/FR0/IRHE/FHJFBEKD/FR0IRHEFHJFBEKD.LARGE.jpg)

dpeek (/member/dpeek/) in reply to piratekitten

whoa 8X

vprevanth (/member/vprevanth/) in reply to piratekitten

i can make it

Warmachine11 (/member/Warmachine11/) in reply to piratekitten

you sure look cute

Warmachine11 (/member/Warmachine11/) in reply to piratekitten

cool im making 1

maccro (/member/maccro/) in reply to piratekitten

Nice...so now everyone has an excuseto stare at your chest. "Wow, nice arc

reactor!".

computer_guy (/member/computer_guy/) in reply to maccro

AHA HA HA AH. Nice.

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TheSniper (/member/TheSniper/) says:

How many would you say you've made thus far, msraynsford?

msraynsford (/member/msraynsford/) (author) in reply to TheSniper

A better question would be "howmany people have managed to follow

these instructions to make their own?"

I've made a fair few now but I did postthis several years ago so it's a slow

and steady trickle.

Caleb Nehrbass (/member/Caleb+Nehrbass/) says:

What I never understood about iron man was

why did he not get the shrapnel removed whenhe got back? He walked around with a power

source in his chest...

Caleb Nehrbass (/member/Caleb+Nehrbass/) says:

Is there a type of clear polymorph?

TheSniper (/member/TheSniper/) says:

(removed by author or community request)

kijo9324 (/member/kijo9324/) says:

go on google and look up"circuitry basics" or something.i had half a course in high school on it and i was probably not there often before i

dropped out.

easy stuff

Colonel88 (/member/Colonel88/) says:

Quick question, how deep is the wood cutout thing? Im guessing around 10 mm

deep, then some 5 mm for the other portions to stick out.

althor015 (/member/althor015/) says:

Hope some one is still reading these and commenting on them. I am trying to build

one of these and am unsure of the wiring schematic.

Which symbols are the resistors and which the lights and how do the outer wiresfollow the ring?

Bah! Wish I had taken electronics classes!

msraynsford (/member/msraynsford/) (author) in reply to althor015

Still reading and commenting, sadly it

sounds like you'd be better offgoogling for some beginner

electronics tutorials.

ironman22 (/member/ironman22/) says:

nice job man i would like to try to make one like these

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I'm very new to this, but I have to ask. Are the resistors supposed to be on thenegative side of the circuit? Do resistors really work that way? In the wiring diagram,

it shows that the positive current goes through the LED, then through the resistor, thento ground. Is this a mistake, or does it not matter which side of the LED they are

placed. The first diagram (from ledcalc.com) shows the resistors on the positive

side....

MrEvolution47 (/member/MrEvolution47/) says:

How many grams/ounces of polymorph did you use?

msraynsford (/member/msraynsford/) (author) in reply to MrEvolution47

I use 35g of polymorph but this willobviously depend on your mould and

I'm managed to eek mine down to the

smallest amount possible now.

dalangalma (/member/dalangalma/) says:

I have a question - where are the resistors in this photo? Are they the little bumps nextto each LED? If so, are they soldered together or did you just glue them in contact?

Fantastic instructable, by the way. I'm really excited to try it myself.

msraynsford (/member/msraynsford/) (author) in reply to dalangalma

They are the little bumps next to each

LED. I pressed the led and the bumpinto blue tac to hold them roughly in

the right place before I soldered them

together. It makes it a darn sight

easier with these small components.

c_nic (/member/c_nic/) in reply to msraynsford

so yeahhh...my iron decided to notwork right plus i couldnt find a tip sharp

enough for this small of work. couldnt

keep a tin for anything. ended up killing

2 leds.

shouldve just bought the complete

thing. there went 30 bucks. haha my

suggestion? buy the complete and

leave it to the professional. :S

ramboboy (/member/ramboboy/) says:

awesome what about the batteries

Darthscout (/member/Darthscout/) in reply to ramboboy

those you put in an Altoids containeror anything else that can house 1 or 2

9 volt batteres

http://www.instructables.com/id/Iron-

Man-Arc-Reactor-prop/ (this isn't hisbut it's really useful)

Neogarex (/member/Neogarex/) says:

thanks

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Jason Amigo (/member/Jason+Amigo/) says:

Since you used one resistor for every two LEDs, did you double the ohms of the

resistors?

HobbitComedian (/member/HobbitComedian/) says:

Here is an image of an arc reactor that I

made using this Instructable as a guide. Mymore complete build out instructions can be

found here: http://www.instamorph.com/?

p=14 Used a new brand of polymorph called

InstaMorph, which you can buy on Amazon or

their website. http://www.instamorph.comThey are Prime eligible too which was nice

since I got free two day shipping as a Prime

member The LEDs I got a Fry's electronics.

They have the perfect stick on surfacemount

LEDs for this project.

(http://cdn.instructables.com/FXU/LLDR/GAPUWXF7/FXULLDRGAPUWXF7.LARGE.jpg)

spaceboy22 (/member/spaceboy22/) in reply to HobbitComedian

cool where did u buy everything

HobbitComedian (/member/HobbitComedian/) in reply to spaceboy22

I got the outer ring (plumbing fixture),

plastic washer and copper wire at the

hardware store.The batteries, clip,

and LEDs I got at Frys Electronics.The plastic I got from

http://www.InstaMorph.com. The

harness I made from velcro and

elastic fabric from Jo Ann's Crafts.

Hope that helps.

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