This gallery includes images from the feature film BATMAN BEGINS, PARTZAN LAB and privately commissioned work. All of the images are copyright protected and may not be copied without prior consent. Photographs concerning BATMAN BEGINS are provided courtesy of WARNER BROS ENTERTAINMENT INC.

These images show the three individually made suits of body armour created for the UNKLEJAM single "WHAT AM I FIGHTING FOR" produced by PARTIZAN in association with VIRGIN RECORDS LTD.

The suits were fabricated using laminated CARBON/A.B.S. patterns lined with fire retardant Plastazote® Foam rubber sheets and bolted together using heavy duty NYLON straps and ACETYL fasteners.

Click the following link to visit the official UNKLEJAM website http://www.unklejam.com/

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ALL HANDMADE was employed by David Forman in association with WARNER BROS ENTERTAINMENT INC to produce a variety of practical body armour items for use in the stunt department for Christopher Nolan's feature BATMAN BEGINS, filmed at Shepperton Studios.

Due to the intense fight sequences and full contact combat designed by the stunt department,  ALL HANDMADE designed and fabricated this covert body armour to be worn underneath both casual clothes and costume props.

Working in association with CJ Munn at ROCKABELLY LIFECASTS to produce the original patterns, life cast moulds were taken from the model's chest, back, biceps, thighs and calves to produce the armour that would protect these areas during the fight sequences.

The moulds were then fibre glassed to create vac-form tools for the next stage in the process.

Once the vac-form tools were made, ABS/High-impact polypropylene was used to create the final body armour protection. In addition to the moulded ABS covering the front and back, Kevlar plates were also used to further protect the stunt performer.   

The final covert chest and back body armour comprised of Kevlar and two layers of High-impact polypropylene covered by Evazote® Foam - A closed cell cross-linked ethylene copolymer foam.

a) Protection level ballistic, bullet proof up to 9mm fmj (dynamit nobel dm11 a1 b2) at 375m/s minimum.

b) Protection level knife, puncture proof exceeding tests of 26 joules minimum energy. 

Protection levels are excepted as a guideline only, supplied by the material manufacturer and not by ALL HANDMADE.

The final body armour could be worn underneath casual clothes as the ABS vac-form sheets conform around the model without causing too much additional bulk and padding. 

Once the body armour was complete ALL HANDMADE fabricated the flying cradle to be worn by Christian Bale's stunt double Buster Reeves. This is the life cast mould taken from Buster which would become the negative impression he would later lay in during scenes involving the stunt department flying rig.

The black fibreglass flying rig.

The final flying rig modelled by David Forman at Shepperton Studios. 

ALL HANDMADE was privately commissioned to design and fabricate this body armour for a group of live action performers to use in their body grinding stage show. ALL HANDMADE retains the copyright for the design, mould making and pattern creation used throughout this project.

Both male and female suits were designed and made to measure using detailed life casts of the performers.

All of the life cast patterns were completely smoothed down to remove any surface detail, primed and waxed ready for the secondary moulding process. 

The original resin life casts were then remoulded in fibreglass to create the 'HERO' moulds for the project. These moulds were then used to create the final vac-form patterns.

In addition to the vac-form patterns which would create the main armour, steel casts were also made from patterns taken off of the original life casts. These patterns include the chest, back, thighs and forearm sections.

This image shows a before and after view of the production process involved in finishing the steel casts. Each of the casts were sanded down to remove any sharp edges and sand blasted to give all of the casts a uniform appearance before being finally waxed and bolted onto the main body armour.

Multiple casts were made of each section of armour so they could be easily replaced at a later date.

Faux carbon fibre High-impact polypropylene was used to create the main body armour pieces from the vac-form patterns. All of the ABS patterns were then coated on the inside with fire retardant Plastazote® Foam rubber. Nylon webbing with Acetyl fasteners were attached to the patterns via stainless steel bolts and Velcro quick release straps were made for easy application and costume changes.

The ABS helmets covered three quarters of the head leaving the back open for additional ventilation. The helmets include a scratch, shatter and fog proof visor which protects the face from dangerous sparks during the show.

The body armour patterns are available in a variety of finishes including clear or frosted ABS. In addition to the main helmet, polished or frosted Perspex bolt bosses secure the clear silicone framed polycarbonate lens goggles in place.

This image shows the proto-type carbon fibre ABS helmet with the first test chrome visor and the final full chrome helmet.

The final male (BLUE) suit.

The final suit comprised of two separate layers of ABS vac-formed armour for each pattern, lined with fire retardant Plastazote® Foam with the steel cast plates bolted onto the outside and flexible electro luminescent wire powered by small portable power inverters creating the external lighting for each suit.  

The male (RED) suit.

The suits allow the performers to grind onto the steel patterns in complete safety. Their faces are shielded from the dangerous sparks and the fire retardant foam inside the patterns reduce the heat transferred from the steel plate to the performer. 

The final male suits together as seen in complete darkness.

The electro luminescent light wire glows outlining the performers bodies as they move and dance around the stage creating a spectacular light show in-between the body grinding act.

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