FM-001 // PULSE BLADE PILOT

A Head-to-Toe Titanfall 2 Cosplay Build Manual

Classification: Field Manual

Build Status: Active Development

Primary Objective: Recreate the Titanfall 2 Pulse Blade Pilot from head to toe using practical, wearable, and repeatable methods.

Mission Overview

The Pulse Blade Pilot is one of the most recognizable Pilot designs in Titanfall 2, but the costume is far more complex than it first appears. It combines a fitted tactical base layer, soft armor, rigid armor, electronics, layered textiles, and a large jump pack into one complete system.

This field manual documents the build from the helmet down to the boots. It focuses on the costume itself rather than the Pilot’s primary weapons. The only weapon-related equipment covered will be the data knife and the optional pulse blade, since both are closely integrated into the character’s equipment and identity.

This guide is intended to help builders understand:

• What each component is

• How the layers interact

• Which parts can be purchased, printed, sewn, or fabricated

• How the costume can be made wearable

• Where electronics and mounting systems should be planned

• Which details matter most for visual accuracy

This manual will continue to evolve as the build progresses, new references are found, and better methods are tested.

01 // BUILD PHILOSOPHY

Before beginning, establish the priorities of the build.

Accuracy

The costume should remain recognizable as the Pulse Blade Pilot even when small details must be adjusted for comfort, mobility, or material availability.

Wearability

Every component should be designed around prolonged wear. Weight, heat, visibility, mobility, and access to batteries or controls should be considered before final assembly.

Modularity

Whenever possible, parts should be removable for:

• Repairs

• Transportation

• Cleaning

• Battery replacement

• Upgrades

• Convention safety requirements

Repeatability

The goal is not simply to finish one costume. The goal is to document a process another builder can understand and reproduce.

02 // REFERENCE AND PLANNING

Before fabrication begins, collect references of the Pilot from multiple angles.

Recommended reference categories:

• Front

• Rear

• Left side

• Right side

• Helmet close-ups

• Vest close-ups

• Jump pack mounting

• Arm armor

• Leg layers

• Electronics

• In-game textures

• Promotional renders

• Community builds

Create a visual checklist and mark each component as:

• Purchased

• Printed

• Fabricated

• Sewn

• Modified

• In progress

• Complete

A complete materials list, vendor list, and file index can be added at the end of the finished manual.

03 // HEAD

3.1 Helmet

The helmet is the visual anchor of the entire costume. Proportion, visor shape, paint, weathering, and lighting will strongly affect whether the final build reads as a Pulse Blade Pilot.

Topics to cover:

• Helmet source

• Scale and sizing

• Interior clearance

• Visor

• Padding

• Chin strap

• Ventilation

• Paint colors

• Surface finish

• Decals and markings

• Weathering

• Mounting internal components

Build Notes

Document:

• Head circumference

• Helmet interior dimensions

• Whether scaling was required

• Visibility through the visor

• Weight

• Heat buildup

• Pressure points

• Changes made after test fitting

3.2 Helmet Electronics

Helmet electronics should be planned before the interior padding is permanently installed.

Possible systems:

• Visor illumination

• Exterior accent lights

• Fans

• Voice amplifier

• Microphone

• Hearing assist

• Battery pack

• Power switch

• Charging port

• Cable management

Key Questions

• Where will the battery sit?

• Can the electronics be accessed without removing the helmet liner?

• Can the lights be turned on while wearing gloves?

• Will fan noise interfere with hearing?

• Are wires protected from movement and sweat?

3.3 Balaclava

The balaclava helps conceal exposed skin around the helmet and creates a cleaner transition between the helmet, shemagh, and undersuit.

Topics to cover:

• Material

• Breathability

• Color

• Full-face versus open-face design

• Helmet compatibility

• Moisture management

• Seam placement

A thin athletic or moisture-wicking balaclava will usually be more comfortable than a heavy cold-weather version.

3.4 Shemagh

The shemagh creates a layered transition around the neck and upper chest while also helping conceal gaps between costume components.

Topics to cover:

• Color and pattern

• Fabric weight

• Folding method

• Attachment method

• Interaction with helmet

• Interaction with vest

• Heat management

The final arrangement should look loose and natural without interfering with helmet movement or covering important vest details.

3.5 Data Knife

The data knife is one of the few weapon-related components included in this manual because it functions as both a tool and a major visual element of the Pilot loadout.

Topics to cover:

• Printed versus purchased version

• Scaling

• Blade safety

• Folding or static design

• Electronics

• Grip finish

• Paint

• Weathering

• Mounting location

• Retention system

• Convention compliance

The knife should be secured well enough for movement while remaining easy to remove when required.

04 // TORSO BASE LAYER

4.1 Undersuit

The undersuit is the visual foundation beneath the armor and equipment.

Topics to cover:

• Base garment

• Fabric

• Color

• Paneling

• Stretch

• Ventilation

• Reinforcement

• Zippers

• Collar

• Matching top and pants

• Printed or sewn surface details

Design Considerations

The undersuit must support the weight and friction of the armor without bunching. High-motion areas should remain flexible:

• Shoulders

• Elbows

• Waist

• Hips

• Knees

• Ankles

Any attachment points added directly to the undersuit should be reinforced internally.

05 // ARMS

5.1 Soft Armor

The soft arm armor provides the layered tactical appearance beneath the rigid plates.

Topics to cover:

• Shoulder padding

• Upper-arm panels

• Elbow padding

• Forearm sleeves

• Quilted sections

• Foam thickness

• Fabric covering

• Strap placement

• Closure systems

The soft armor should create volume without restricting elbow movement.

5.2 Hard Armor

The rigid arm armor includes the visible printed or fabricated shell components.

Topics to cover:

• Shoulder armor

• Bicep armor

• Elbow components

• Forearm armor

• Scaling

• Print orientation

• Reinforcement

• Sanding

• Priming

• Paint

• Weathering

• Straps

• Magnets

• Buckles

• Velcro

• Mobility testing

Fit Test

Perform the following movements before final painting:

• Raise arms overhead

• Cross arms

• Bend elbows fully

• Reach behind the back

• Hold a prop

• Access vest controls

5.3 Gloves

The gloves should visually match the costume while preserving dexterity.

Topics to cover:

• Base glove

• Knuckle protection

• Finger mobility

• Touchscreen compatibility

• Added armor

• Cuff integration

• Paint or dye

• Weathering

• Grip

Gloves should be tested with the data knife, electronics, buckles, and any handheld props.

06 // VEST SYSTEM

The vest is the structural center of the costume. It supports the front accessories, rear electronics, and potentially parts of the jump pack harness.

6.1 Vest Base

Topics to cover:

• Vest source

• Vest style

• Color

• Fit

• Shoulder adjustment

• Side adjustment

• Internal reinforcement

• MOLLE or custom webbing

• Hidden mounting points

• Weight distribution

The vest should be fitted over the completed undersuit and soft armor, not over ordinary clothing.

6.2 Chest

The chest area contains several recognizable equipment components.

6.2.1 Magazines

Topics to cover:

• Reference shape

• Number required

• Print files

• Dimensions

• Material

• Paint

• Markings

• Weathering

• Retention

• Pouch fit

• Dummy versus functional containers

The magazines should appear full-sized without creating unnecessary weight.

6.2.2 Power Box

The power box is a prominent technical component and can serve as a practical housing for electronics.

Topics to cover:

• Exterior shape

• Dimensions

• Mounting

• Hinged or removable cover

• Battery storage

• Switches

• Charging access

• Cable exits

• Ventilation

• Labels

• Paint

• Weathering

This component may become the main power hub for the vest and rear systems.

6.2.3 Dust Cover

Clarify the exact reference and function of this component in the final draft.

Topics to document:

• Location

• Shape

• Material

• Attachment

• Flexibility

• Color

• Weathering

• Relationship to nearby pouches or electronics

A reference image should be included so readers understand which piece is being discussed.

6.2.4 Pouches

Topics to cover:

• Number

• Size

• Placement

• Base pouches

• Custom covers

• Closures

• Functional storage

• Convention essentials

• Weight distribution

Useful pouch contents may include:

• Phone

• Wallet

• Batteries

• Cooling pack

• Repair kit

• Business cards

• Water

• Emergency hardware

6.2.5 Chest Electronics

Possible systems:

• Accent lighting

• Status lights

• Power indicator

• Sound module

• Push buttons

• Cable routing

• Hidden battery access

• Master power control

The electronics should support the costume rather than overwhelm it. Subtle, purposeful lighting will usually appear more convincing than excessive brightness.

6.3 Back

The rear vest area must be designed around the jump pack and harness.

Topics to cover:

• Reinforcement

• Mounting plate

• Harness routing

• Quick-release points

• Cable routing

• Ventilation gap

• Weight transfer

• Accessibility

6.3.1 Rear Electronics

Possible systems:

• Jump pack lighting

• Battery distribution

• Fans

• Sound

• Power connectors

• Detachable wiring

• Emergency shutoff

• Charging port

Use connectors that allow the jump pack to be removed without cutting or pulling wires.

07 // JUMP PACK

The jump pack is the largest and most technically demanding component of the build.

Topics to cover:

• Reference breakdown

• Overall dimensions

• Scaling

• Weight target

• Print segmentation

• Structural frame

• Hollow sections

• Reinforcement

• Assembly

• Thruster housings

• Surface details

• Grilles

• Tubing

• Paint

• Weathering

• Electronics

• Harness

• Mounting

• Quick release

• Transportation

• Storage

Critical Design Goals

The jump pack must:

• Stay close to the body

• Avoid excessive backward pull

• Transfer weight to the torso or hips

• Remain removable

• Survive normal convention movement

• Fit through doors

• Be transportable by vehicle

The pack should be test-worn before final detailing.

08 // LOWER BODY

8.1 Pants

Topics to cover:

• Base pants

• Color

• Fabric

• Fit

• Reinforcement

• Knee articulation

• Cargo pockets

• Added panels

• Strap anchors

• Belt loops

• Connection to chaps

• Connection to spats

The pants should allow kneeling, climbing stairs, sitting, and walking without pulling against armor attachments.

8.2 Pistol Mount

This section covers the mount or holster only, not the weapon.

Topics to cover:

• Location

• Drop-leg height

• Platform

• Straps

• Belt connection

• Stability

• Quick release

• Empty display option

• Convention restrictions

• Compatibility with chaps

The mount should not swing during movement or interfere with sitting.

8.3 Chaps

Topics to cover:

• Shape

• Material

• Pattern

• Attachment

• Waist mounting

• Thigh straps

• Edge finishing

• Surface details

• Weathering

• Mobility

• Interaction with holster

• Interaction with knee area

The chaps should move naturally without twisting around the legs.

8.4 Spats

Topics to cover:

• Pattern

• Fabric

• Closure

• Armor inserts

• Strap placement

• Connection to pants

• Connection to boots

• Weathering

• Preventing upward movement

Spats help create the layered lower-leg silhouette and conceal transitions between pants and boots.

8.5 Boots

Topics to cover:

• Base boot

• Sole

• Height

• Comfort

• Added armor

• Toe treatment

• Heel treatment

• Gaiter or spat integration

• Paint

• Dye

• Weathering

• Insoles

• Long-term wear testing

Boots should be selected early because their shape affects the spats and lower-leg armor.

09 // OPTIONAL GEAR

9.1 Pulse Blade

The pulse blade is optional because it may be impractical or restricted at some events, but it remains one of the defining elements of the character.

Topics to cover:

• Reference dimensions

• Blade material

• Flexible or rigid construction

• Rounded edges

• Lighting

• Diffusion

• Handle

• Battery placement

• Activation switch

• Mounting

• Display mode

• Convention safety

• Transportation

A removable blade section may make the prop easier to transport and approve.

9.2 Arc Device

Topics to cover:

• In-game reference

• Location

• Scale

• Shape

• Electronics

• Lighting

• Attachment

• Power

• Removal

• Weathering

10 // ELECTRONICS SYSTEM PLAN

Because electronics appear across several components, the finished manual should include a unified electrical plan.

Suggested categories:

• Helmet power

• Chest power

• Rear vest power

• Jump pack power

• Pulse blade power

• Shared batteries

• Independent batteries

• Charging

• Switches

• Connectors

• Voltage

• Wire routing

• Fuses

• Emergency shutoff

A diagram should show which components are electrically connected and which remain independent.

11 // ATTACHMENT SYSTEMS

Create a dedicated section explaining the methods used across the costume.

Possible methods:

• Sewn webbing

• Elastic

• Nylon straps

• Side-release buckles

• Chicago screws

• Rivets

• Snaps

• Magnets

• Velcro

• Zippers

• Bolts

• Quick-release pins

• Hidden hooks

• Harness plates

For each method, document:

• Where it was used

• Why it was selected

• Weight capacity

• Ease of removal

• Known weaknesses

12 // PAINT AND WEATHERING

Establish a consistent finishing system across all rigid components.

Topics to cover:

• Primer

• Base colors

• Metallic layers

• Masking

• Decals

• Stencils

• Edge wear

• Scratches

• Dirt

• Oil

• Heat staining

• Matte finish

• Satin finish

• Clear coat

Weathering should tell a consistent story. Parts exposed to contact, heat, movement, or the environment should show more wear than protected surfaces.

13 // SUITING UP

Document the order in which the costume should be worn.

Suggested sequence:

1. Undersuit

2. Pants

3. Boots

4. Spats

5. Chaps

6. Pistol mount

7. Soft arm armor

8. Hard arm armor

9. Vest

10. Chest equipment

11. Gloves

12. Shemagh

13. Balaclava

14. Helmet

15. Jump pack

16. Data knife

17. Optional gear

This order will likely change after testing.

Include notes on:

• Which parts require assistance

• How long suiting up takes

• Bathroom access

• Battery checks

• Emergency removal

14 // FIELD TESTING

Before convention use, test the full costume in stages.

Static Test

Wear the complete costume for 15 to 30 minutes indoors.

Mobility Test

Walk, sit, kneel, turn, use stairs, and reach all controls.

Heat Test

Wear the costume under conditions similar to the intended event.

Duration Test

Increase total wear time gradually.

Failure Test

Identify:

• Loose straps

• Cracked prints

• Hot spots

• Fogging

• Battery failures

• Unreachable switches

• Cable snags

• Weight imbalance

Every failure should be documented as part of the manual.

15 // CONVENTION LOADOUT

Create a checklist for event use.

Suggested items:

• Costume

• Helmet

• Jump pack

• Gloves

• Data knife

• Optional pulse blade

• Spare batteries

• Charger

• Adhesive

• Velcro

• Zip ties

• Tape

• Small tools

• Touch-up paint

• Water

• Cooling supplies

• Business cards

• Storage tote

• Costume stand

• Safety documentation

16 // LESSONS LEARNED

This section should be updated throughout the build.

For each component, record:

• What worked

• What failed

• What took longer than expected

• What cost more than expected

• What would be changed

• What another builder should know first

This may ultimately become the most valuable part of the entire manual.

17 // SOURCES AND RESOURCES

The completed field manual should include:

• Reference images

• STL files

• Sewing patterns

• Vendors

• Materials

• Electronics

• Paints

• Tools

• Community builders

• Tutorials

• Estimated costs

• Estimated print times

Clearly identify whether each resource was:

• Personally used

• Personally tested

• Community recommended

• Unverified

18 // FINAL BUILD INDEX

A summary table can be added at the end.

Component	Method	Status	Source	Notes
Helmet	Purchased and modified	In progress	TBD	Electronics planned
Balaclava	Purchased	TBD	TBD	Moisture-wicking
Shemagh	Purchased and arranged	TBD	TBD	Color match needed
Data knife	3D printed	TBD	TBD	Safe blade required
Undersuit	Modified garment	TBD	TBD	Paneling required
Soft arm armor	Sewn and fabricated	TBD	TBD	Mobility priority
Hard arm armor	3D printed	TBD	TBD	Scaling test needed
Gloves	Modified	TBD	TBD	Armor additions
Vest	Modified tactical vest	TBD	TBD	Main support system
Jump pack	3D printed and reinforced	TBD	TBD	Weight critical
Pants	Modified	TBD	TBD	Chaps integration
Pistol mount	Purchased or fabricated	TBD	TBD	Mount only
Chaps	Sewn	TBD	TBD	Pattern needed
Spats	Sewn	TBD	TBD	Boot fit required
Boots	Purchased and modified	TBD	TBD	Comfort priority
Pulse blade	Fabricated	Optional	TBD	Event restrictions
Arc device	Fabricated	Optional	TBD	Reference needed