Earlier this year we decided to build a female Winter Soldier (Bucky Barnes) cosplay for Julie to match my Captain America strike suit. Long before our first full suit of armor, we've been 3D printing props and costume pieces for our various cosplays such as Power Ranger helmets, weapons, and accessories.
For this cosplay, we chose to go with @Do3D.com's female version of Bucky's mechanical arm. This was important because many of the models out there are designed for a male, and the musculature is exaggerated and oversized. They were the only maker we found with a great looking female version of the armor that is slimmer but still muscular.
After purchasing the file, we imported it into Armorsmith using Julie's avatar to size it properly. We printed each half on our Creality CR-10S Pro at .16mm layer height on the stock .4mm nozzle. This is a higher resolution print than our full armor build due to its intricate design, we didn't want to lose too much detail when sanding.
With the arm printed, we added an attachment method of 1" elastic that loops around the opposing arm. We also used elastic between the two pieces of the arm to keep them together when the elbow isn't bent or posed.
We sanded down the arm by hand from using 120-240-320 grit sandpaper and primer. From there we applied a gloss black ground coat, and Spaz Stix Mirror Chrome. One buffed, the paint has a reflective finish.
We added the red star using Duplicolor's Metalcast paint which is translucent. The chrome paint underneath helps create depth and shine.
We paired the arm with a screen-accurate Winter Soldier jacket from White Sheep Leather, tailored to fit a female frame.
For the hand, we used an extra set of Iron Man fingers we had printed for Rescue combined with a tactical fingerless glove and a silver 4-way stretch fabric underneath.
The arm was then weathered with Angleus flat black leather paint, airbrushed in between the lines to give a realistic look and pop.
Cap & Bucky are ready for battle!