Jeffery
Jeffery
Report

Laser Cut Wooden Ironman with Articulated Joints

Instruction
Ironman flat pack new.xcs
Ironman flat pack new
.xcs
Application scenario
Laser processing (60min)
Machine & module
xTool S1
40W
Compatibles · 13
Material used
1/8"(3mm) Basswood Plywood
737
6982

Information

      New files uploaded 25 Jan 2026  Added file formats for LBRN2, XCS, DXF, SVG and AI

I made some major modifications to the parts and the layout
    

Instruction

1

Step1: Assemble the head

Laser Cut Wooden Ironman with Articulated Joints instruction: step 1 - Assemble the head
Preview
Laser Cut Wooden Ironman with Articulated Joints instruction: step 1 - Assemble the head
Preview
Laser Cut Wooden Ironman with Articulated Joints instruction: step 1 - Assemble the head
Preview
14 More images

Gather all pieces for the head.

The original pattern was messed up so I made the corrections.

Follow the pictures.

Some of the pictures show the messed up pieces.

The corrected pieces are on the new pattern.

2

Step2: Torso Assemble

Laser Cut Wooden Ironman with Articulated Joints instruction: step 2 - Torso Assemble
Preview
Laser Cut Wooden Ironman with Articulated Joints instruction: step 2 - Torso Assemble
Preview
Laser Cut Wooden Ironman with Articulated Joints instruction: step 2 - Torso Assemble
Preview
7 More images

Layout and assemble the main body section.  Again there were bad pieces in the pattern which I fixed.

There were unnecessary tabs that did not belong. And holes that needed to be there.

There is a square piece with a notch in it.  The notch faces the front of the torso.

I will take more pictures on the next build.

 

 

3

Step3: Assemble arms

Laser Cut Wooden Ironman with Articulated Joints instruction: step 3 - Assemble arms
Preview
Laser Cut Wooden Ironman with Articulated Joints instruction: step 3 - Assemble arms
Preview
Laser Cut Wooden Ironman with Articulated Joints instruction: step 3 - Assemble arms
Preview

Layout pieces as shown.  Note that the arm with the had is the right arm.

I put a little glue on the T piece so the gear and the round piece stay on.

I am adjusting the T pieces to hold on to the gear and round pieces so they snap into place.

4

Step4: Build the legs

Laser Cut Wooden Ironman with Articulated Joints instruction: step 4 - Build the legs
Preview
Laser Cut Wooden Ironman with Articulated Joints instruction: step 4 - Build the legs
Preview
Laser Cut Wooden Ironman with Articulated Joints instruction: step 4 - Build the legs
Preview
Laser Cut Wooden Ironman with Articulated Joints instruction: step 4 - Build the legs
Preview

Build the legs. 

Carefully assemble the legs.  The flat side is the inseam.  

The larger fork piece goes to the back of the leg.

The cross section gets a little glue and the foot piece goes on.

5

Step5: Finish assembly

Laser Cut Wooden Ironman with Articulated Joints instruction: step 5 - Finish assembly
Preview

Put glue on the end of the neck and insert into the top square hole on top of the torso.

Carefully put a very little glue on the sides of the arm T piece to hold it into the arm socket.

Do the same for the legs.

 

Once the pieces are dry they should stay in place.

6

Step6: You're done

Once again I'll be making modifications so that the joints will stay in place without glue.

 

Have fun and leave a comment with pictures of your build.

Comments

Remixes

xTool Supplies Used in This Project

xTool S1
xTool S1
1/8"(3mm) Basswood Plywood
1/8"(3mm) Basswood Plywood

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