This Halo 3 Marine cosplay was built and worn by Andrew Mandaliti and is a full scale costume created using a mix of digital fabrication, traditional prop making, and textile work.
Construction started with custom scaled 3D Pepakura files printed on 110 lb cardstock. Each part was cut, folded, and glued by hand. A coat of polyester resin was applied for strength, followed by multiple layers of fiberglass.
Once the fiberglass cured, a mixture of Bondo body filler and fiberglass resin, commonly known as Rondo, was applied to the interior. This created a smooth inner surface for comfort and added structural reinforcement. Each piece was then sanded using multiple grits of sandpaper in preparation for paint.
The armor was finished in military green and weathered using a combination of acrylic and spray paints. The undersuit was built using BDU clothing sourced from a US army surplus store, with additional custom fabric elements added where needed.
The armor is worn using a system of straps and buckles that allow each section to clip on and secure in place. The black thigh pads were made from mattress foam and wrapped in sewn black fabric. A range of military pouches and accessories were added to complete the costume.
The helmet includes a motorcycle visor and multiple internal cooling fans in both the mouthpiece and helmet. The SMG prop was made from Pepakura and filled with Rondo to give it weight. A later DMR prop was built from stacked foam core layers.
This build was designed for durability, wearability, and accuracy for convention use.
