The Pulse Blade Pilot Costume is complete. This article documents the development process behind it, from the original in-game design to the finished costume.
We’ll update the article as each new part of the series is published, keeping the full development journal in one place. New readers can start from the beginning, while returning readers can continue with the latest update.
The first part focuses on the arm protection. Although it is only one section of the costume, it required a separate development process.
DEVELOPMENT JOURNAL
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Part 1 — Arm Protection: From Game Model to Primer
Available now -
Part 2 — Arm Protection: Painting, Graphics, and Final Assembly
Coming next
Last updated: 2 August 2026
Part 1: Arm Protection
HOW MUCH WORK GOES INTO JUST THE ARM PROTECTION?
We set out to make the Pulse Blade Pilot Costume from Titanfall 2 as close to the in-game original as possible. But a design created for the screen does not automatically work on a real person.
Today, we’re focusing on one part of the finished costume: the arm protection. Although it is only one section of the full costume, it required its own development process.
FROM THE GAME MODEL TO A REAL PERSON
The process starts with the original in-game 3D model. We cannot use it directly because it was designed for a digital character rather than a real body.
We rework the geometry, print prototypes, and conduct fittings to balance in-game accuracy with comfort.
Through multiple fittings on different people, we refine the scale, proportions, placement, and fit. This helps preserve the recognizable Pulse Blade Pilot silhouette without making the arm protection look bulky or disproportionate on the body.
CREATING THE PRESS MOLDS
Once testing is complete, we create separate 3D models for the press molds. Printing them is only the first stage.
Each surface is leveled by hand, the print lines are removed, and the geometry is refined. These masters are then used to produce durable resin press molds.
FORMING THE MAIN ABS PARTS
Once the press molds are ready, we form the main arm protection parts from ABS plastic.
ABS is lightweight, durable, and holds its shape well. Thermoformed ABS parts are stronger and have a smoother, more even surface than parts produced directly by 3D printing.
CASTING THE DETAILED COMPONENTS
Thermoforming cannot reproduce every complex curve or fine surface detail with the required accuracy.
The smaller detailed components are therefore cast separately. We create molds, fill them with two-part plastic, and produce each component in the required shape.
This allows us to use thermoforming for the larger ABS parts and casting for components that require finer detail.
EVERY PART IS FINISHED BY HAND
After thermoforming and casting, every component is processed by hand.
We remove excess material, smooth the edges, and prepare each surface for the next stages.
READY FOR PAINT? ALMOST.
Before painting can begin, we need to prepare the many small graphic elements that will later be applied as decals. The Pulse Blade Pilot Costume includes a particularly large number of them.
The next stage begins with primer.
This is where Part 1 ends — just before painting begins.
In the next update, we’ll continue with the arm protection and show how the parts move through primer and painting, how the graphic elements are applied, and how the final finishing and assembly are completed.
This page will be updated when the next part is released, so the complete development story remains available in one place.
