S.T.A.R.S.





When my husband first cosplayed a character from Resident Evil, I made the stupid comment that I could cosplay Nemesis. Apparently my husband took me seriously. This was another quite challenging build, but mostly done by my husband, but wearing it is even more challenging, so i'm claiming it as my project too.





Again, not many in progress shots of this cosplay, so it's mainly just a write up.

This project was put together in 2 parts simultaneously, the main body, and the head. Let's look at the head first.

The head of Nemesis is the most defining feature, so it took quite a bit of time to sculpt it so it would fit, be functional, and look right.

We first started with a 3D print of my head, this was then built up in particular areas with tin foil, and then covered with a layer of monster clay. The rest of the features were sculpted out of more clay, leaving a gap where the teeth would go as these were also 3D printed.

Once the sculpt was complete, we began making a mould. This was made out of a thick layer of plaster in order to give the latex the opportunity to cure. This was a 2 part mould, first with a thin coat of plaster to pick up the detail, followed by thicker layers for strength. Unfortunately the plaster did not cure fully, so we had quite a bit of shrinkage around the split, in order to later fill it with latex, we used a lot of hot glue to seal the gap.

We literally filled the mould with latex, using an inflated plastic bag to take up some space in the middle, and left it for a few hours to build up a sludge on the plaster mould. Once we removed the rest of the latex, this left a thin ish skin on the plaster which then we left to cure overnight.

Once we split the mould apart, we were left with a latex mask, this was painted with acrylics mixed with latex, and the 3d printed teeth were fixed in place.



While we were doing the mask, we were also covering me in foam and contact cement. The torso was built by using a compression top, sprayed with contact cement and layered up with some old mattress cover foam. We then carved this into shape using long blades, and stuck on more foam where needed to give it the shape.

The heart box was 3D printed, and made hollow to allow a speaker to sit inside it. The wires for this went through the pipe, into the shoulder, under the arm pit, and terminated at magnetic switches stuck to the abdominal area. These switches would allow a magnet embedded in the gloves to trigger sounds to come from the heart box.

The last layer was a skin made of polyester wadding, this smoothed out a lot of the bumps in the foam. We added on some scraps of fake leather where the exposed skin would be and began the wrapping.

The wrapping was made from black tarpaulin, this was the closest, cheapest alternative to carbon fibre fabric. We first started with the wider sections, attaching them using a mixture of contact cement and superglue. The edges were sealed with a strip of black duct tape on the underside to prevent fraying.

We made the skirt separately, using a strip of EVA foam as the belt, again wrapped in tarp, and the skirt edged with weighted string to make it hang properly.

Once all the wrappings were done, we also created the helmet by casting the eye again, and attaching it to a generic helmet pattern made out of foam, this allowed an alternative head. We printed out some cuation stickers, and attached some fake 3d printed staples, painted up the exposed skin, and the body was done.

The hands were made by attaching 3d printed finger tips to some gardening gloves, extending these with a thin strip of EVA foam, padding it out with more foam round the forearms, covering the fingers and hands in latex, and then adding more wrappings.

The last touch we did was create a breathing tube, this was because despite the holes we were able to make in the mask, the air flow was terrible and restricted the time I could wear it for significantly.



Nemesis is nothing without a weapon. We had the suit made ready for CosExpo, but didn't have the time to make the launcher, however we decided that Nemesis needed it ready for the next convention.

To begin with, we got a size reference, took screenshots, and printed out different angle view of the launcher at the correct size. The model viewer in the game was perfect for this and we were able to download a 3D file which made the screenshots even easier.

Once we had the print outs, we used a drain pipe as the base, and began by wrapping it in 10mm EVA foam.

Using the blueprints, I put a threaded metal rod at an angle through the pipe to provide a sturdy handle to take the weight of the launcher as that would be how it was carried most of the time.

We then added different parts of the launcher, building boxes out of EVA foam and glueing them on, using the print outs as a blueprint. The glowing rods were large glow sticks for ease, and were added in by making the back part of the box fully detachable.

The whole launcher was coated in Seal Prime from PolyProps that had been watered down with white spirit, and then painted. Once the paint was dry, a thick coat of flexible sealer was added, and then an oil wash, followed by another layer of sealant, before we called it done.