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Project: Mandalorian armor cosplay
Purpose: To combine my love for Star Wars and art. To learn how to sculpt, paint, weather, sodder and sew.
Concept and sculptor:
Jesús González
15 years ago, I built my first Mandalorian armor using a bicycle helmet, plastic signs, and a few found objects. It was a bit rough, but the experience taught me invaluable lessons about craftsmanship.
Fast forward to last year, I decided to tackle the project again — but this time with a more refined approach. I used 3D printed parts for precision, incorporated kitbashed details for the armor and weapons, and focused heavily on weathering and painting techniques. I also ventured into the realm of electronics to add depth and functionality to the cosplay.
With a strict timeline of just three months and a limited budget, I set my sights on debuting the armor at the London Star Wars Celebration convention. The pressure was on, but with a clear plan in place, I dove in headfirst.
I made mistakes along the way — I repainted the helmet several times and experimented with different techniques until I got the weathering just right. One of my proudest achievements was creating a modular helmet system. Using magnets, I could swap props to change the helmet's profile and give the cosplay multiple versions.
The goal was always to tell a story with the armor, and I designed two different “modes” for the convention:
Cyberpunk Mode: This version featured a jacket with a Teotihuacan-inspired spray-painted symbol, layered with faux-leather armor details. I added electronics to the jacket to give it a futuristic, high-tech feel, and paired it with weathered slacks and a hoodie that acted as an under-armor layer. The helmet had a white brim to match the hoodie and tie the look together.
Western Mode: Here, I aimed for a classic rugged aesthetic. I weathered a poncho, adding greebles to give it a Star Wars twist. I repurposed old boots and added canvas layers to give them a “rough-traveler” look. The helmet was kept minimalist, with only a few attachments to evoke a more traditional bounty hunter vibe.
Overall, this project was an incredible learning experience — not just in terms of building the armor, but in storytelling and the craftsmanship that went into each piece. And the convention? Well, that’s a story for another time.