At some point, our workshop started filling up with Helldivers armor. Freshly formed chest plates were waiting to be trimmed. Sanded parts were moving to paint. New sheets of plastic were already heating for the next batch. That was when we realized our mistake: we had waited too long to make this costume.
One Wrong Cut
Every set begins with a flat sheet of ABS plastic, heated to 140°C and pulled over a mold until it takes the shape of the armor. It happens quickly, but the next stage leaves almost no room for error. One cut too deep, and the entire part can be ruined. The formed parts are trimmed and sanded by hand because even a small flaw will show through the paint. But vacuum forming cannot reproduce every small shape and detailed component. Smaller parts of the Helldivers costume require a different process: casting plastic is poured into molds.
Where Every Millimeter Matters
This is how we make the pocket PC, buckles, and decorative mounts. Each cast part has to be refined by hand. These are the smallest and most precise details, where every millimeter matters. Remove too much material, and the part may no longer fit where it belongs. The helmet is cast the same way. We remove the excess material, even out the edges, and sand the surface. At this point, one unnoticed defect can follow the helmet all the way to paint. Once every part is ready, the costume can move on to the stage where mistakes become much harder to hide.
Paint Reveals Everything
Painting begins long before the first brushstroke. Each part is primed, then painted white in the areas reserved for Helldivers insignia and symbols. The logos are positioned on the helmet and chest plate, followed by the yellow accents that define the design. This is another stage where a small shift can affect the entire result. Smaller details are painted by hand, while masking tape keeps the black sections and lines clean. Finally, we add weathering to make the armor look like it has already seen combat. The paintwork is complete, but the biggest test is still ahead.
Built to Wear
The most important thing about armor? It has to be comfortable enough to wear. That starts with the undersuit and pouches. We use a laser to cut the eco-leather parts into precise shapes, then assemble them, sew on the Velcro, and add the details needed to match the in-game design. The undersuit is made to individual measurements, so it holds its shape without restricting movement. Add the gloves, cape, and boots, and the full set is ready for final assembly.
Preparing for Deployment
This is where we find out whether every earlier decision was correct. The shoulders lock into place, the chest and back connect, the belt and pouches are added, and hidden straps keep the leg armor secure while moving. Some load-bearing fasteners are made from aluminum and stainless steel, while soft inner padding keeps the full set comfortable to wear. One misplaced attachment could pull the armor out of position. But once the last part was secured, everything finally worked together.
Then we stepped back and saw the finished Helldivers costume for the first time.
That was when we realized our biggest mistake.
We should have made it sooner.
Demand quickly forced us to rethink part of our production, but seeing the complete costume made one thing clear: Helldivers armor deserved a place in our workshop much earlier.
