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vrogy halo 3 armor.jpg

Meet Michael Vroegop, aka “Vrogy.” He made this set of Halo 3 marine armor for the last Dragoncon. His site doesn’t include a lot of details about his process, but I’m pretty sure he starts with digital 3D models, converts them using Pepakura, has them CNC cut, and then folds them up for use either as direct parts or as molds. Vrogy, if you see this, you might take a sec to fill us in down in the comments about how it’s done. Also, please consider this a gilded invitation to submit a project to our 2009 Make: Halloween Contest.

Sean Michael Ragan

I am descended from 5,000 generations of tool-using primates. Also, I went to college and stuff. I write for MAKE, serve as Technical Editor for MAKE magazine, and develop original DIY content for Make: Projects.



  1. neko68k says:

    sets of pepakura or pdf halo armor are available. build them like you would any papercraft. there is a process to fiberglass/resin coat the craft to be sturdy. check out the forums on

  2. says:

    He congratulated me on the plywood chess set making here before I realized it, so I’m sure he’ll be along shortly.

    I’m not sure how he got the designs, but the actual armor bits is vacuum formed plastic using MDF cut on a shopbot as a mold.

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