The Samus Varia suit is Lady Allison Cosplay's most difficult build to date. The main body of the suit is made from EVA foam. The arm cannon is foam and uses PVC pipe to create the articulating joints. The helmet was modeled based on game files and 3D printed at home in ABS plastic. The suit features over 300 programmable LEDs. The EVA parts of the build took approximately 120 hours to complete, with the helmet modeling and print time running about 110 hours.
The LEDs and hand cannon alone are enough to make anyone wow'ed by this cosplay. Building Samus' suit from Metroid is no easy task, yet Lady Allison knocked it out of the park!