Power Armor Exo
A Fallout-inspired pneumatic power-armor exoskeleton, built to lift 200 lb and deadlift roughly 2,000.
- Year
- 2024
- Context
- R&D engineering intern at Hacksmith Industries
- Timeline
- Summer 2024
- Discipline
- Pneumatics, Exoskeletons
My main project for the summer of 2024 at Hacksmith Industries was a pneumatic power-armor exoskeleton, focused on the power arms and built to look and work like the suits from the Fallout games. We built two versions of the arms, and the second used what we learned from the first.
I contributed to the pneumatic design and interfaced it with a state machine that controls the exo’s movements. I was involved in every phase of the build, and I led the preliminary research.
The build
01
Pneumatic design
We chose pneumatics for their power and portability. One system raises the arms, closes and locks the cuffs, and inflates the air cuffs that fit the suit to its wearer. I learned how to design a pneumatic system, and how to make one system do many jobs.
02
Figure finishing
Figure finishing is the craft of turning a machine into a character. For this suit, that meant 3D-printed armor that made the sheet-metal exoskeleton look like the power armor from the games. I was the main line of communication with our print vendor, and the lead on testing, painting and fitting the printed pieces.
03
Sheet-metal manufacturing
The frame is built from sheet aluminum to save weight. That choice taught me how to design for sheet metal, and how to manufacture three-dimensional forms from flat stock.
Videos
