Vault Dweller Cosplay from Fallout
Character: Vault Dweller
Version: Metal armor
Series/Game: Fallout 4
When: 2024/2025
Techniques used: wig styling, hand-painting, FDM resin printing, eva foam crafting, real rust making, weathering
About the costume
In 2024, I had the opportunity to work with Amazon Prime Video Italia, who asked me and Ermetriel to create two Fallout-inspired cosplays for a private event in Rome. The event was dedicated to Italian actors, voice actors, talents, and influencers.
With just a few days to prepare, we brought to life two Vault 111 dwellers, complete with Pip-Boys and weapons. We chose to portray the “clean” versions of the characters, as if they had just stepped out of the Vault into the wasteland for the first timeโtrue to the iconic opening moments of Fallout.
Later on, for a private and highly selective cosplay photography event called โIl Volta,โ I upgraded my Vault Dweller costume. I added custom-made metal armor pieces, detailed weathering effects, rust accents, and other post-apocalyptic touches to give it a more authentic, battle-worn lookโtrue to the gritty aesthetic of the Fallout universe.
Fallout Cosplay photos
Photography by Photolisteners (2025)
Private Amazon Prime Event (2024)
Vault Dweller cosplay Tutorial
I finally gave my Vault Suit the post-apocalyptic love it deserved!
I started with a base suit I bought onlineโbut even in the smallest size, it was way too loose (especially at the waist!). So I tailored it for a much better fit, added heavy weathering, 3d printed greeblies, and gave it that authentic Wasteland Survivor vibe.
Extra weathering for the boots and same for the pipboy, greeblies & gunnnnn with fake rust.
While the armor has real rust.
I also completely remade the bracer using faux leather, a more accurate shape, and details closer to the original Fallout design.
Want to see the process? Many work-in-progress photos and videos are available in my Instagram and TikTok!
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