BLACK LIGHTNING

OVERVIEW

For this project, I was tasked with interpreting the costume design provided by DC, Warner Bros, and LJ Shannon. It was my responsibility to create the draft the engineering drawings, measure, prototype, sew, and manage the manufacturing for this iconic character.

The ask was for it to be comfortable, functional, durable, and light up bright enough to outshine the set lighting.

ROLE

Anthropometric Interpretation
Project Management
3D Modeling
3D Printing
Injection Molding
Electronics Routing
Electronics Design
Pattern Making
Textile Design
Sewing

 WE START WITH THE DESIGN

The client provides an initial design concept to begin the conversation of the intended scope.

Character: Black Lightning (Warner Bros., DC)
Designer: Laura Jean Shannon
Concept Artist: Alan Villanueva

MATERIAL R&D

The project required specific areas of the suit to contain hot wires. I chose a combination of neoprene materials to protect against electric currents, even in moisture or damp conditions, enhancing safety and durability.

ELECTRONICS HOUSING

The materials used to house the electronics of the suit included…

  • Urethane

  • Silicone

  • Neoprene

  • PETG

Which were manufactured using the following techniques:

  • Injection Molding

  • Vacuum Forming

  • Industrial Sewing

LIGHTING TESTS

Aesthetic success is vital, but the true test is a product's functionality and durability. It should withstand daily use while being both attractive and resilient.

FORM MEETS FUNCTION

i was very pleased to successfully achieve the complicated trifecta of aesthetics, comfort, and functionality.

RESULTS AND TAKEAWAYS

This was the most ambitious light-up costume since Tron: Legacy, and DC had large expectations for the delivery of this project. The true success of this project was the fact that the costume was wearable, comfortable, safe, and stunt capable. Something not other light-up costume had ever succeeded in.

Key takeaways from this project are:

  • Wire weakness over repeat flex areas: I learned the lesson of wire reinforcement and anatomical bend avoidant wire routing. A hard learned lesson that has allowed for many years of success.

  • The surfboard: This is the last project that I allowed for an oversized chest plate (cuirass). The only major issue this suit experienced was the fact that a person cannot clap their hands in front of them if armor extends outside of the armscye. “It’s like trying to hug a surfboard” - Cress