Baldur’s Gate 3 – Dame Aylin armor piece by piece

In my latest post about Dame Aylin’s construction I did a general overview on the materials and techniques I used but I’d like to show you the process piece by piece for you to see the construction of this armor in detail.

The process is basically the same with every part:

  • Pattern making by wrapping things in duct tape.
  • Craft foam construction.
  • Structural attachments made of PVC foam and thermoplastics.
  • Small 3D printed resin ornaments.
  • Chrome vinyl wrapping.
  • Paint and weathering using acrylic paints.
  • Attachments, which are mainly Velcro tape everywhere, nylon straps and plastic buckles.


I wrapped my head replica with tape in order to make the helmet patterns. I used cardboard to pattern the sides.

Once the base was done, I designed and prepared the details to be cut with my Cricut Maker 3.

As the frontal pieces are very thin, I added some Worbla to give them stiffness.



Once again, I wrapped my mannequin using masking tape in order to make the patterns.

I made a craft foam bodice as a base.


I took the chance that the original armor has these weld marks on the breast to make the darts of the pattern.

Small ornaments are designed using Fusion360 and printed in resin. Files are available in my shop.



Breastplate finishings

I first wrapped each piece in vinyl and then I glued everything together on the foam bodice. I personally like to make breastplates joined on the shoulders. I can do that because I have a very tiny head. It’s a personal obsession as I think this way armors look better.

As you can see, I made the scaled pieces on the back removable so I can wear the costume with and without wings.

Upper limb

Shoulder pads

All the little details are 3D printed.

Elbow pads

These pads were especially difficult to make as they have this intricate shape. In the original design you can see they’re made of several little pieces and that’s what I tried to emulate. With the base piece done, I added two layers of 2mm foam on top to smooth the volumes.


Gauntlets are mainly made using 2mm craft foam, so I added a layer of Worbla for them to keep the shape.


Finger armor was 3D designed and printed.

The piece on the back of the hand was made using 2mm craft foam and the details were also 3D printed.

Lower limb



As the thigh armor in the original design looks so thin and lies tightly against the body, I directly glued it to the chain mail pants.

Knee pads

Leg armor

The upper prominent parts of the leg armor were made using PVC foam for stiffness. To make the relief between pieces, I cut in angle 5mm foam sheets and glued them together. This way the edges pop.



All the small ornaments in this costume have been designed using Fusion360 and 3D printed. Files are available in my shop.

In the particular case of the buckles, I designed the frame and I used the prong from other metal buckles I had at home. I didn’t trust that piece made of resin.

Scale mail

The whole scale mail is made of craft foam. I designed the scale rows and send them to my Cricut Maker 3.

They’re glued together with cyanoacrylate and glued to the suit with contact cement. As I sad in my first post about this costume, I’m very happy with how it looks but I don’t like it’s very stiff so I can’t comfortably move. I’ve thought about different alternatives such as silicone, other kind of design for craft foam, 3D printing, sequins… but I think I’m finally making a scale suit with the Parallel Life Studios fabrics. And I’ll leave this foam scale mail just for photo shooting.


Textile elements in this armor are those hanging clothes on the legs. They’re made with faux leather and lining from Antoñita Jimenez and decorated with golden bias tape and iron on vinyl.

Wig and make-up

Aylin’s wig has no mystery. I bought this lace front wig on Aliexpress and styled it with 17 Kg of hairspray.

One thing you’ve asked me a lot about is the golden make-up details. They’re painted using Rimmel London’s Wonder Swipe liner.

And that’s it! I just have to finish the sword, that is already printed and waiting for me to glue and paint it and make the wings which is going to be quite a funny challenge for me. You’ll be informed of my progress.

As always, feel free to comment!

Wanna learn to make your own costumes?

My craft foam cosplay guide is now available!

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