Roxanne Wolf
(Five Nights at Freddy's: Security Breach)
My very first experience with 3D printing. The character is from the horror survival game, Five Nights at Freddy's: Security Breach. I spent around 900+ total hours printing this suit. Every part of the model had to be modified for printing and wearability. I started the planning stage of this costume in October 2023 and ended up finishing it in March 2024.
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I knew this was a character that required a specific approach for the most faithful rendition I could possibly do, so 3D printing was the way to go. I went through a lot of trial and error figuring out the best way to make this work. I had to teach myself 3D modelling on a computer since I primarily work with old school methods like clay, so this process was definitely one of the more ambitious things I've ever done. The only parts of Roxy that weren't printed are the middle torso and hair pieces. The torso was made out of EVA foam and the hair and tail were sculpted in WED clay then casted in latex.
For each project I do, I start off with a 1:1 scale drawing so I can get an idea of how big everything has to be as well as if it'll be functional in the long run. My finished rendition of Roxy is about 6'5 feet tall, which stayed true to the scale drawing I did of her.
Every part that was printed had to be sanded with 60 grit sandpaper and an electric sander. Using an electric sander isn't entirely necessary but it saves a lot of labor time. After I used the 60 grit I went to a 220 grit to smooth everything down. Each piece was then primed and later sprayed with the final color. In the game, Roxy's colors differ greatly depending on the lighting. To ensure I could stick with a consistent, accurate color, I used the actual model's paint texture HEX code. Her main color is a grayish blue, so I matched a spray paint to be that color exactly. After everything was painted, I went over everything with a gloss varnish spray to seal the paint and give her that glossy look she has in the game.
I used a reciprocating saw to trim down any parts that were too tight to wear. The legs and hips were the most challenging to get correct because there was a bit of a 'sweet spot' for each piece to fit right. If I trimmed too much, the costume wouldn't look right. If I trimmed too little, it would cause major problems when being worn such as pain.
Nearly all of the eyes with the characters I make are created by a company called Fourth Seal Studios. I knew Roxy's eyes had to be special since they're an important part of her character in the game. After seeing the Five Nights at Freddy's film, I wanted to have eyes that were similar to the ones shown in the movie. So I went to the main company I always go to and asked if I could have eyes made for Roxy that were based on the ones from the film (similar iris). They told me they were actually the people that created the eyes for the movie. So we talked back and forth (me being very shocked since I've known these awesome people for quite a while now) and they created some AMAZING eyes for Roxy. They used the same molds from the film, as which the eyes are 3 inches in diameter. I couldn't be happier to have such a beautiful and special piece of artwork incorporated in the suit.
Roxy's hair and tail were sculpted in WED clay. I used a total of 200 pounds of clay to sculpt both pieces. I figured 3D printing these parts wouldn't be logical since I wanted them to have flexibility and they needed to be molded. I used hydrocal plaster to mold the sculptures. Afterwards I used slip cast latex to create a type of skin for the hair. The latex takes in all of the detail from the mold. I filled in the empty space with upholstery foam and paper towels since both helped the hair and tail keep their original shape without distorting it.
This isn't a costume I can wear for very long, but every part of this process was a super fun learning experience. I've ended up tweaking a bunch of parts every now and again to increase wearability time. The total cost for every material used to create this costume has been around $4,000-$5,000. Roxy was my introduction to the world of 3D printing and I plan on using a lot of the techniques I've gathered for the other three main animatronic characters in the FNAF: Security Breach game (Freddy, Chica, and Monty). I'm aiming to have the others completed by the end of 2024, and each one will be a wearable costume that will all have their debut at Son of Monsterpalooza in October.
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