Real-Life Superhero:
Fabio Pavanello’s Cosplay Therapy and our 3D Printed Wolverine Armor
Cosplay therapy transforms passion into social impact, merging creativity with tangible support in pediatric wards. One story that truly inspires is that of Fabio Pavanello, a motorsport R&D professional, who has dedicated himself to bringing smiles to children through cosplay.
From personal promise to shared mission with MATI OdV
A few years ago, Fabio made a personal promise: to turn his cosplay passion into an act of kindness.
He started visiting hospitals dressed as superheroes, spreading joy to children and families during challenging times.
Initially working alone, Fabio later partnered with MATI OdV, making cosplay therapy a mission.
They visited pediatric oncology wards across Piedmont and Lombardy, including Regina Margherita in Turin and Maria Letizia Verga, creating genuine connections, evoking emotions, and providing children with moments of normalcy. The empathy behind the superhero costume makes a real difference.
Challenges of the first Wolverine chest piece in PLA
Over time, Fabio’s Wolverine costume became iconic. However, the original chest piece, made from PLA, proved inadequate: rigid, fragile, and uncomfortable for long wear or close interactions with children.
A more flexible, durable, and soft solution was needed to allow natural movement and safe, warm hugs.
Prototek's contribution with 3D Printing using TPU HP MJF
When Fabio contacted Prototek, we understood the project was more than a technical challenge; it was about supporting a deeply human gesture. We proposed a new chest piece using TPU (thermoplastic polyurethane), offering flexibility, abrasion resistance, and comfort.
TPU HP Multi Jet Fusion (MJF) 3D printing allowed us to create a lightweight, ergonomic armor that moves naturally with Fabio, eliminating hard edges while maintaining the character’s aesthetic.
Every detail was designed for safety, functionality, and comfort, based on practical tests, ergonomic feedback, and iterative engineering.
This approach also highlights the versatility of TPU 3D printing, enabling rapid prototyping, adjustments, and improvements based on real-world feedback. Each modification enhances both comfort and visual accuracy, ensuring that the costume not only looks authentic but also supports the volunteer’s movements. Cosplay therapy becomes safer, more engaging, and truly impactful.
3D printing for Cosplay Therapy: the true value of the project
Thanks to TPU 3D printing, the Wolverine chest piece now enhances cosplay therapy visits, providing both durability and comfort. Fabio’s mission, bringing hope, strength, and smiles, is at the heart of the project.
For Prototek, this collaboration demonstrates how technology can support socially impactful initiatives.
In this case, 3D printing is not just a tool but a way to make acts of kindness more effective and human-centered.
Enhancing the Cosplay Therapy experience with custom 3D Design
Beyond durability and comfort, custom 3D printed cosplay armor allows precise personalization to fit each volunteer’s body and character needs. Using advanced 3D modeling, we adapted the Wolverine chest piece to Fabio’s movements, ensuring flexibility, safety, and ease of wear during extended visits.
This tailored approach also reduces fatigue and allows volunteers to interact naturally with children, making each cosplay therapy session more immersive and effective.
By combining technical expertise with empathy, 3D printing transforms costumes from static props into functional tools for social impact, proving how innovation enhances human connection.
Moreover, 3D printing enables cost-effective replication of costume components, allowing multiple volunteers to participate in cosplay therapy programs.
This scalability maximizes outreach, spreading joy to more children across hospitals efficiently.
Bringing innovation and solidarity together
The synergy of innovation and compassion proves transformative.
By combining advanced 3D printing technologies with a volunteer mission, cosplay therapy becomes more than an art, it becomes a lifeline for children in hospitals.
If your organization seeks tailored, durable, and functional 3D solutions, contact us to explore how advanced additive technologies can support your projects.
