Black Knight: Making-of

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«Crafting a full armor from the ground up in just one month ? Eaaaasy !»

Among the three costumes we wanted to bring with us to Blizzcon in 2015, the Black Knight was the last one we made. One month before our departure to Los Angeles, the costume was barely started (a small piece of chainmail here, a small piece of Pepakura there)… and the stress began to build up slowly !

A huge amount of work awaited us : helmet, sword, full armor, chainmails, lights… The days felt long, but we took the challenge on, and after one month, the Knight came to life (one day before taking off, but still).

More than a year after its inception, here is (at last) the making of our Black Knight 😉

Reference pictures

It all begins with some research work, to find good reference pictures.
Our starting point was the illustration made by Alex Horley for the Black Knight card in the video game Hearthstone : Heroes of Warcraft.

Since parts of the character were hidden, Marie re-drew him entirely based on this picture, while adding the missing parts from the World of Warcraft in-game 3D models.

Chevalier Noir Hearthstone
Original drawing by Alex Horley

croquis armure cosplay
Sketch made by Marie

croquis épée wow
Sword template drawn digitally

épéé warcraft modèle
Sketch made by Marie


Some pieces were first crafted in Pepakura (see tutorial) by using a 3D model extracted from World of Warcraft.

First, the helmet. Despite this step being optional, it gave us a life-size reference so we could sculpt with Worbla afterwards.

logiciel pepakura cosplay
Converting the 3D model to Pepakura

pepakura casque cosplay
Printed Pepakura file

pepakura cosplay glue
Cutting the Pepakura with the precision cutter

pepakura cosplay casque
Gluing the Pepakura pieces together

pepakura cosplay
The finished Pepakura helmet!

The helmet’s horns were cut from this Pepakura, and the shoulder horns were also made using the same method.

We tried a new technique to in the hope of saving some time : filling the Pepakura pieces with insulating foam.

cornes mousse expensive
Filling the horns with insulating foam

pepakura mousse expensive
Result after a bit of cleaning

Once the pieces were full, we worked on the shape by cutting sharp edges. We then covered everything with Worbla.

cornes worbla cosplay
Horns covered with Worbla

épaules cornes worbla mousse
All horns, covered with Worbla


1. Helmet

For the helmet, we first made a Kobracast base from the shape of my head. This shape was then covered with foam plates encased into Worbla.

Once the base was rigid, the sculpting began. We started with the simpler parts : the scales on the top of the head. As done previously, we cut foam plates with the right shape (thanks to tape patterns), covered them with Worbla on both sides and sticked them to the helmet.

casque worbla cosplay
Early photo of the helmet in Worbla

cobra cast casque cosplay
Insides of the helmet

patron casque worbla
Patterning with paper tape

patron mousse cosplay
Pattern result on foam

Here comes the though part : sculpting the face directly with Worbla. We put some Worbla’s Black Art «sausages» on the surface to create elevation and we shaped them.

We added the lower part of the helmet, made of foam and Worbla.

Then, we attached the horns (remember the ones in Pepakura covered with Worbla ?) by screwing them from the inside of the helmet.

sculpture casque worbla
Shapes are drawn with a black marker

sculpture worbla black
Sculpting the nose with Worbla Black

casque worbla black sculpture
We put Worbla on the shapes

armure worbla casque
The worbla part isdone!

2. Other armor pieces

Like previously done, we made the part bases with thick foam covered in Worbla.

jambe armure worbla
An early pauldron

épaulières worbla cosplay
Almsot finished Worbla pauldrons

dos armure worbla patron
Backplate, incoming details are drawn on the surface

dos led worbla armure
Details done. The red parts are coloured Worbla Transpa Art

torse worbla armure
Starting the Worbla coating on the torso plate

patron armure torse
Once the Worbla is in place, we drawn the coming details


3. Skulls

Making the skulls was a bit more complicated. We needed them to be hollow so we could hide all the lights and cables.

Marie started by sculpting them with Plastiline directly onto the Worbla.

sculpture plastiline worbla
Marie sculpting Plastilin

crane plastiline sur worbla
Sculpting done

armure worbla plastiline
Same process for every part

I made a mold out if these skulls with Mold Max 40 silicone.

Once again we tried some new techniques… this time we made a cast only using Worbla Black by pushing it directly into the mold. And it worked pretty well !

And thus, we got hollow and light pieces that will stick to the Worbla armor without any problem.

silicone moulage smooth-on
Applying silicon directly on the piece

moulage plastiline worbla
Same process for every part

moulage worbla black silicone
Result : a small skull silicon mold

cranes wrobla black
Skulls made with Black Worbla

moulage worbla black
Drilling the eyes open with Dremel

épaulière warcraft cosplay
It fits perfectly! 🙂

armure torse warcraft
…On the torso as well!

4. Runed Soulblade

Joris made a wooden body for the sword (handle + blade). On top of this basis, we sculpted the blade with foam and covered it with Worbla.

Patterns are «engraved» by hand onto the Worbla using sculpting tools.

épée mousse worbla
Pattern drawn onto the Worbla

épéé cosplay worbla
Pattern engraved onto the Worbla


The parts were primed, then painted in an iridescent black tone. Once the layer was dry, the sections that needed to stay black were covered with tape, and the others sections sprayed with a layer of silver paint.

peinture argenté worbla
Silver layer sprayed on top

peinture armure worbla
Black paint base sprayed on the torso

casque worbla appret
Black paint base sprayed on the helmet

peinture casque armure
Colouring with the brush

casque armure cosplay warcraft
Helmet finaly done!

To finish, we add some accent by dry brushing blue/purple iridescent paint on the black sections. And some black paint on the silver ones.

Chain Mail

To craft the Black Knight’s chain mails, we opted for a darker plain grey.

If you want to learn more about the technique we used to do the chain mails, you can read our tutorial here.

cotte de maille cosplay
Ready to make some chainmail

cottes de mailles cosplay
Ring by ring we chain the mail

cotte de maille aluminium
It’s so very time consuming

cosplay sopalin
Super Kitchen Roll !


Obviously, the Black Knight wouldn’t be anything without some super badass red aura.

We made the skulls’ eyes and all of the other lit areas with Worbla’s Transpa Art. These transparent pieces were sanded on the inside and painted with red stained glass paint.

Then we attached the LEDs behind the parts using Worbla.

led worbla cosplay
LEDs sealed behind the skull with Worbla

led lumières armure cosplay
Proud of the results!

Full costume

1. At Blizzcon

The costume was ready just in time for Blizzcon, you can check out the video and pictures right under here.

We hope you have enjoyed this making-of ! 🙂

Blizzcon cosplay wow

armure Black Owl Studio
Photo : Cosportraits

Warcraft Cosplay
Photo : Cosportraits

Blizzcon Cosplay
Photo : Blizzard / Greg De Stefano

2. Photoshoot with JBM at the Ortenbourg Castle

armure led worbla cosplay
Photos : JBM-photos

cosplay world of warcraft
Photos : JBM-photos

cosplay wow armure
Photos : JBM-photos

armure worbla épéé
Photos : JBM-photos

3. At conventions

cosplay armure
Photo : PMD Photograph

cosplay armure worbla
Photo : PMD Photograph

cosplay worbla
Photo : Stella Nera

ecg cosplay armure
Photo : ECG / Cool ADN
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Mael Alos, 26 ans est Webdesigner/Webmaster freelance. Il est fan de jeux-videos et de SF, ses spécialités sont le Worbla, la résine et le silicone.

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