I think much like taking a paper pep and changing it to suit EVA foam, you would have to do the same when translating to fabric. (especially non-stretch fabrics) Al you'd need to do is create a 3D model of the costume, unfold and scale it and we could take pattern grading to a whole new level.ĭoes anyone have the time/skills to run any experiments on this? I feel like it has the potential to bring pattern making into the 21st century. The same could be done with almost any fabric costume. Print it out and tape it up, lay it over some blue spandex, and BOOM, perfectly sized Superman costume. Then cut off the head and hands, load it into the Pepakura program, and unfold it as if it's foam. Here's where the idea started: You could create a low poly model of a person, scaling it to fit your proportions. What if you could apply the same techniques to create patterns for fabric costumes? We all know that Pepakura is great for converting 3D shapes into planar surfaces.but why just use it for paper, foam, or cardboard. These programs are free to use.Here's an idea I've been kicking around in the back of my head for a while now, I just know I don't have the time or skills to try it out properly, so I decided to offer it up here to see what you guys made of it. Once unpacked, PDO files can be opened by Pepakura Designer or Pepakura Viewer. The pattern files are packed in a ZIP format. PDF patterns are also supplied if you do not want to install these applications, but the 3d preview helps a ton in assembly. The 3d models used to make these patterns are created and/or modified by me. If you have a 3D printer, you can download the extra STL models I used for the helmet tube, shoulder ridges and shoulder led strips: I found these were easier to add to the cosplay as a 3D print rather than try to make them in eva foam. If the link doesnt work, go to my facebook page > photos > see all > scroll down until you see ‘samus aran varia suit’ album. If you need help assembling it, check out my Samus Aran Varia suit build album on my facebook. Only one version of each armor piece is added, you can mirror or duplicate patterns to get the other side etc

To get the rounding I have in my armor, make sure to ‘make up’ by rounding off the polygonal shapes where needed, and add sharp corners where the Varia suit requires them.

You should only cut along the red shell lines.

To get the least additional seams possible, merge darts in the patterns together and heatshape where possible. You can emphasize these lines in 3D by lightly dremeling the corners before glueing it together. The patterns seams are aligned with the dark texture lines in the Varia suit reference itself, so minimal seams are achieved.

Pepakura patterns to foam patterns