The Making of a 3D Printed Alien Xenomorph Suit

3D Printing & Imaging
The Making of a 3D Printed Alien Xenomorph Suit


A man by the name of James Bruton has been working on a 3D printed costume for a couple months now, and his designs are finally starting to come together. With a Lulzbot TAZ 3D printer with a dual extruder and whole bunch of plastic filament, Bruton has created a fantastically fun cosplay suit that will surely stand out in any crowd he goes.

Bruton has been building science fiction props and costumes for years and helps to run the Southampton Makerspace in his free time. In the past he has made an Iron Man suit, Android bipedal legs, a Short Circuit Johnny 5 robot, various Star Wars props, and even a dollar store Terminator Endoskull; all of which are documented on his website.

One of his latest projects is inspired by the well renowned sci-fi horror Alien film series and incorporates several standalone 3D printed parts that are fashioned together. Each of the pieces typically consist of two types of filament, ABS and Ninjaflex.

The whole outfit hasn’t been completed yet and is still a working progress, but a good chunk out of the project is out of the way. Already the fingers and handbacks have been created which connect to the arms.


The finished head holds an inner jaw mechanism with a servo that allows for the hinges of the jaws to open and close. The shoulder brace has been also been printed and attached to the head mount & chest area giving the suit a distinguished outline so far.


The progression of Bruton’s work can be found on the website linked to above as well as through a series of Youtube videos. Part 9 of the project can be seen in the video below where Burton describes how he made the shoulder tubes and mounting for the suit. We look forward to seeing what it looks like once it is all completed.

For more of James Bruton’s project, be sure to visit the website.

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I'm a virtual reality, wearables, and technology art journalist who focuses on emerging trends in the maker, hacker, and inventor cultures. I like to travel around from place to place researching what is being made.

View more articles by Matt Terndrup