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.
The complete development and production journal is now collected in one place. Readers can start from the beginning or move directly to any part using the index below.
The first two parts focus on the arm protection. Part 3 moves on to the leg protection, including the textile base, sewing, graphics, and final fitting. Part 4 covers the load-bearing system with attachments, from its hidden textile layers to the final assembly and fitting. Part 5 completes the series with the production process behind the Pulse Blade Pilot Helmet.
DEVELOPMENT JOURNAL
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Part 1 — Arm Protection: From Game Model to Primer
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Part 2 — Arm Protection: Painting, Graphics, and Final Assembly
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Part 3 — Leg Protection: From Game Model to Final Fit
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Part 4 — Load-Bearing System with Attachments: Development and Assembly
- Part 5 — Helmet: Production Process
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.
Part 2: Arm Protection
FROM PRIMER TO FINAL FIT
Part 2 continues exactly where the previous chapter ended: after primer.
PAINTING IN LAYERS
After primer, all parts are painted in their base color. We use automotive-grade painting materials, applied by professional painters using automotive painting techniques.
Then the longest stage begins: we mask everything that should not be covered by the next layer of paint, apply a new color, add stencils, and repeat the process again and again until the result is clean and precise.
The automotive materials and professional application do more than create a smooth, even finish. They ensure that the paint remains securely bonded and does not peel or fade over time. We have used this approach since 2018 and have not received a single complaint about either issue.
BUILDING THE SOFT ARM LINERS
At the same time, we make the soft arm liners.
Before cutting the fabric, we first develop the patterns in specialized 3D modeling software.
Using prepared patterns, we cut dense Cordura and Velcro fabric, finish the edges with binding tape, and sew on the attachment points.
This allows the liners to keep their intended shape, stay visually close to the in-game original, and securely hold the protective components.
BRINGING ALL THE PARTS TOGETHER
Once the painting and sewing are complete, we move on to assembly.
We join the finished cast and ABS parts, then add webbing, Velcro, and the remaining fasteners.
Thanks to the prototypes, fittings, and precise calculations completed earlier, every component fits into place as intended.
THE FINAL FITTING
Everything is now ready for the final fitting.
We put on the completed arm protection and evaluate the result. The soft textile base helps the parts sit comfortably on the arm, while individual fasteners securely hold each component in place.
At the same time, the construction remains mobile and preserves the appearance of the in-game original.
ARM PROTECTION COMPLETE
The arm protection is complete.
NEXT: LEG PROTECTION
With the arm protection complete, we’re moving on to the leg protection. We’ll show that development in the next update.
Part 3: Leg Protection
FROM THE GAME MODEL TO THE FINAL FIT
In Part 3 of our development series, we’re moving on to the leg protection for the Pulse Blade Pilot Costume.
STARTING WITH THE IN-GAME MODEL
As with the arm protection, the process begins with the original in-game 3D model.
We scale the parts to real-world dimensions and adjust their shape and proportions so they fit a real person while preserving the appearance of the original design.
A HIDDEN BUT IMPORTANT PART
Sewing plays a major role in the leg protection.
We also make a separate belt—an almost invisible but important part of the construction. It is hidden in the references and the in-game model, but without it the costume would be incomplete.
GETTING THE VOLUME RIGHT
The textile base required especially careful development.
We adjusted the patterns several times and selected the density and thickness of the materials so the parts would maintain the required volume without looking too bulky or restricting movement.
SEWING THE TEXTILE BASE
After cutting the fabric, we sew together the upper and lower sections of the liners, finish the edges, and add all the necessary webbing and fasteners.
In the original references, most of the textile parts are finished with decorative binding. To reproduce this detail, we had to add binding to 29 separate sections across different parts. And believe us, this is a labor-intensive process.
ADAPTING EVERY MARKING
Even after the sewing is complete, the work is not finished.
The leg protection includes more than 30 individual graphic elements. Each one is adjusted separately to match the shape and size of the specific textile part.
We tested several application methods before choosing DTF heat-transfer printing. It produced the most durable result, so all the graphics are transferred onto the fabric using this method.
PUTTING IT ALL ON
The costume is now ready for a fitting.
We begin with the belt and attach the thigh guards. Then we put on the boot covers, lower-leg guards, and knee pads.
The separate construction of each component makes the leg protection easier to put on, while all the parts together preserve the recognizable silhouette of the character.
LEG PROTECTION COMPLETE
Here is the finished leg protection, with all the textile components, markings, and protective elements brought together in the final result.
NEXT: LOAD-BEARING SYSTEM WITH ATTACHMENTS
In the next part, we’ll show how the load-bearing system with attachments was developed and assembled.
Part 4: Load-Bearing System with Attachments
THE SYSTEM AT THE CENTER OF THE COSTUME
This is Part 4 of our Pulse Blade Pilot Costume series. In the previous parts, we covered arm protection and leg protection.
Now we’re moving to the center of the costume: the load-bearing system with attachments.
With its layered textile construction, adjustable webbing, MOLLE sections, functional pouches, back-mounted components, and lighting, this may be the most complex system in the entire costume.
THE LAYER YOU ALMOST NEVER SEE
Beneath the load-bearing system is the jacket.
Very little of it remains visible in the finished look, but it provides the base that makes the costume feel complete.
BUILDING THE LOAD-BEARING BASE
The load-bearing system is sewn from durable Cordura and built with functional MOLLE attachment points.
The inner layer uses soft Velcro-compatible fabric to secure the internal components. Between the layers is removable padding that can be replaced when needed.
Because the padding is removable, the inner space can also accommodate compatible cooling inserts purchased separately without changing the visible appearance of the costume.
FUNCTIONAL POUCHES, NOT JUST PROPS
We make each pouch separately, reproducing its shape, proportions, and placement from the original design. Once the textile construction is complete, we add the required markings and attach the finished pouches to the MOLLE system.
The pouches reproduce the appearance of the in-game equipment and remain fully functional, with space for carrying personal items. Two of them include removable imitation cartridges. Once these are removed, the space inside can also be used for storage.
ASSEMBLING THE BACK-MOUNTED SYSTEM
Next, we move to the back section.
We install the plastic components, attachment points, and lighting in the back-mounted system. The LEDs recreate the characteristic glow of the equipment shown in the game.
BRINGING ALL THE COMPONENTS TOGETHER
Once every element is ready, final assembly begins.
The load-bearing system adjusts in both volume and height through its webbing. The internal components attach with Velcro, while the pouches, communications unit, and other accessories connect through the MOLLE system.
This modular construction makes it possible to position the individual elements where they belong and keep them securely in place.
ADAPTED FOR REAL WEAR
Recreating the in-game silhouette was only one part of the task. The complete system also had to remain practical on a real body.
During development, we conducted approximately a dozen fittings on different people. These fittings helped us refine the proportions, height, volume, placement, and attachment of the individual components.
Adjustable webbing, separate attachment points, functional MOLLE, Velcro connections, and quick-release buckles allow the costume to be put on without assistance. They also help keep the armor, pouches, and attachments in their intended positions during walking, posing, and active movement.
THE FINAL FITTING
Now we can try on the completed load-bearing system.
We put it on over the costume, adjust the fit, and check how all the components work together.
Each element can be positioned individually, while the complete construction preserves the layered, recognizable silhouette of the Pulse Blade Pilot.
LOAD-BEARING SYSTEM COMPLETE
The load-bearing system with attachments is complete.
From the hidden jacket and padded base to the functional pouches, adjustable connections, and illuminated back-mounted system, all the layers now work together as one structure.
FINAL PART: HELMET PRODUCTION
The final part shows how the Pulse Blade Pilot Helmet is produced, from preparing the mold and casting the shell to painting, electronics, visor installation, and final assembly.
Part 5: Helmet Production
HOW THE PULSE BLADE PILOT HELMET IS MADE
The Pulse Blade Pilot Helmet was developed earlier and has since become one of our best-selling products. In this final chapter, we’re focusing on production: how each helmet moves from the silicone mold to the finished, fully assembled result.
PREPARING THE SILICONE MOLD
The process begins with the silicone mold. We apply talc to its inner surface and blow away the excess, then place the mold into a rigid support shell made specifically for its shape. This shell holds the flexible mold in the correct position during casting.
Here is one detail most people never see: the mold cannot be stored empty. A helmet must always remain inside it. Otherwise, the silicone can gradually deform and lose the correct shape.
ROTATIONAL CASTING
We place the support shell into the “drum”—a centrifuge that rotates in three planes.
Next, we mix a casting plastic developed specifically for this process and pour it into the mold. As the machine rotates, the plastic is distributed evenly across the mold walls, forming the main helmet shell.
After the plastic has been distributed, the mold is left for three hours until the material has fully cured.
REMOVING THE HELMET FROM THE MOLD
Once the plastic has cured, we remove the support shell and begin pulling the silicone mold away from the helmet.
Although the silicone is flexible, this is not a quick step. Demolding one helmet takes approximately 15 minutes and requires steady physical effort.
CLEANING AND PREPARING THE SHELL
The helmet is now out of the mold, but it is not yet ready for painting.
At this stage, we cut away all unnecessary plastic, including the remaining casting sprues, and open the area for the visor. We also drill the holes that will later be used to attach the separate components.
Finally, we sand the surface to level it and create better adhesion for the primer and paint.
21 SEPARATELY CAST COMPONENTS
In addition to the main shell, the helmet includes 21 separate components.
Each part is cast individually and then finished by hand: excess material is removed, the edges are cleaned, and the surfaces are prepared for painting and assembly.
We also produce the supporting components separately, including silicone light diffusers and holders for selected electronic elements.
PAINTING ONE LAYER AT A TIME
Painting begins with preparation. We apply two coats of primer, allowing each coat to dry completely.
Next, we mask all parts of the helmet that must remain dark, leaving the dome and graphic elements accessible. White paint is applied to the white areas.
We then mask part of the graphics and apply yellow paint to the required markings. After that, the dome is painted beige.
For the next stage, we mask the entire helmet except for the dark graphics on the dome and apply the dark paint.
Once all the color layers are complete, we remove the masking tape, add the damage effects, and protect the finished surface with clear coat.
Every coat of primer, paint, and clear coat must dry completely before the next layer can be applied.
BUILDING THE ELECTRONICS
Before final assembly, we prepare the electronics.
We design and assemble the entire electronic system for the helmet ourselves, including the electronic circuit. The system is prepared separately before being installed inside the finished shell.
FORMING AND INSTALLING THE VISOR
The visor also requires several separate stages.
First, we cut the required shape from acrylic and apply the engraving. The acrylic is then heated in an oven until it becomes flexible.
While the material is still flexible, we place it inside the helmet and allow it to cool and hold the required shape. Only after that is the visor securely fixed inside the shell.
FINAL ASSEMBLY
We attach all the separately produced helmet components with screws and install the prepared electronics.
Next, we add a foam layer inside the helmet. The internal components are then covered with a liner designed and sewn specifically for this helmet.
Finally, we secure the battery compartments and complete the remaining connections.
Final assembly of one helmet takes approximately six hours.
HELMET COMPLETE
The main shell, 21 separate components, visor, electronics, lighting, foam layer, and interior liner are now assembled into the finished Pulse Blade Pilot Helmet.
The Complete Development Story
FIVE PARTS, ONE COMPLETE COSTUME
Across five parts, we followed how the Pulse Blade Pilot Costume moved from the original in-game design to a complete wearable result.
The arm and leg protection required geometry adaptation, prototypes, molds, thermoforming, casting, sewing, graphics, and repeated fittings. The load-bearing system brought together the hidden textile layers, MOLLE attachments, functional pouches, adjustable connections, and illuminated back-mounted components. The final chapter showed how the helmet is cast, finished, painted, equipped with electronics, and assembled.
Each section uses its own production process, but all of them were created to work together as one complete costume while preserving the recognizable Pulse Blade Pilot silhouette.
