Iron Man's suit

Posted on 22nd Apr 2015 -
How close are we to a real Iron Man suit?

Okay. If we are just speaking of an armoured suit that augments the strength and weaponry of a person then we are extremely close. If we are speaking of something with all of the primary abilities of the Iron Man character such as flight, clean infinite power and his repulsor beams, that may never become a reality. The current version in the comic books is even more insane than the movies, with a suit made entirely of nanites that can repair or replicate itself and any weaponry on the fly...

So how close are we? First, I'll break down the things we (unfortunately) cannot do, and then, I'll treat you to some really awesome stuff we can...

How close are we to a real Iron Man suit?
The Stuff We Can't Do


We just cannot have a flying suit like Iron Man's. Not exactly, anyway. The main reason for this is the tiny rocket engines and repulsor beams.

Repulsor Beams

One of the key components of the Iron Man suit is its repulsor beams, and that's a kind of technology we may not have anything like for a very long time (if ever). The only logical explanation is that they are some kind of graviton manipulator. This is so far out of our current technological realm that we can't even begin to guess how it could possibly be done with what we currently know.

Arc reactor

It is not entirely clear how the suit's reactor works. It's smaller than a soda can, but can produce more power than the miniature reactor on a Virginia class nuclear submarine. It has something to do with zero point energy and a continuous self sustaining reaction that would appear to break most rules of thermodynamics that we know of. It could possibly be some type of cold fusion reaction, but again, we have no clue how to even begin doing this in such a small size. No reaction is 100 % efficient, so the waste heat alone from such a reactor would likely be enough to cook the person inside the suit.

What We Can Do

Okay. So that was a bit of a letdown. Now, what could we do? The answer is, actually, a lot!


We could almost exactly copy the original Mark I prototype armor from the comics either right now (today) or in the next few years.

The Mark I above is not all that different from Raytheons XOS 2 powered armor suit below. It's stronger than a human and has heavier armor than a person could otherwise carry.

The video below shows how the enhanced strength from the exoskeleton allows a soldier to lift 100 kilograms without any effort at all. A soldier would also then be able to carry a much heavier pack and armor. Lastly, the suit reduces fatigue even for physical activities like pushups. In other words, it does all the work for him.

A prototype design concept for future development, which can also be seen in the background of the video above, lies below.

Not to be outdone, Lockheed Martin has its own powered suit called HULC.

It has less overall strength but still reportedly allows a soldier to carry a 100 kilogram load, and it seems they have working units that can function untethered. Still, there's no word on how much of that 100 kilogram load is currently being devoted to batteries.


While nothing like an Arc Reactor, we do expect a tethered version that could walk alongside a vehicle carrying the suit's generator in three to five years. In this case, it would mostly be used to lift heavy materials in and out of vehicles for deployed soldiers. This would allow a very small team to rearm a vehicle or chopper in the field, while still allowing them to quickly unload bulk supplies and move on out of harms way. In six to 10 years they expect to be able to power the suit with its own internal power supply. The most limiting factor is battery technology, but that is slowly improving.

We would have trouble with finding a power source and would need to recharge frequently. This is actually okay because the Mark I had the exact same issue! The Mark one used "transistors" (capacitors they meant possibly?) to power the suit and allow it to be charged rapidly from any wall outlet. Unfortunately it ran out of juice very often. Still so far so good. You didn't expect us to start out with a Mark VIII dynamic nanite colony suit did you?


As I stated before, we can't have flight like the Iron Man from the movies, but the Mark I didn't have that capability either. Supposedly, it was still able to make short jumps or bursts of flight using "compressed air". We have actually had designs similar to this for decades.

The military designed a series of "jump jets" or "rocket belts" that used a highly concentrated mix of hydrogen peroxide along with a catalyzing agent to create jets of high intensity steam, allowing a person to fly mostly vertically, which is just what the Mark I did! Some other models used liquid nitrogen instead. Either one can be deadly if the fuel tank ruptures. Being dissolved by 90 % pure hydrogen peroxide or frozen by liquid nitrogen is not a pleasant way to go.

Okay, so that is obviously very cool but with a flight time measured in seconds and a world record of only 45 metres, this won't do for a superhero or a soldier.

Enter the Martin Technology JetPack.

In this video we see the device climb to 1,500 metres and deploy an emergency parachute at 900 metres. This was actually flown by remote control in a chaser helicopter with a dummy, but that also shows how a navigation computer or assistant could help with flight in an emergency. The flight system is bulky but it could be attached to the XOS and used to enter hostile territory. After you arrive, you park it somewhere inconspicuous and move in to deal out some Iron Man-style justice. Just don't forget where you parked it.

Lastly, if all that wasn't enough for anyone dreaming of soaring like a jet as opposed to a tiny helicopter, there is one last option.

Yves "Jetman" Rossy has pioneered a wearable jet flight pack. It has the drawback of not being powerful enough to reach flight altitude on its own, but once in the air, it can perform take on some impressive flight.

As daring innovators like these continue to create amazing devices, it is only a matter of time before some type of human scale personal flight system becomes viable.


Now for the Navy we could go a different route for an Iron Man suit's propulsion.

Yes it does have a small 3 metres long chaser boat and does not fly very high but it could allow for some useful tactical advantages. This thing even runs on normal fuel. It could propel a Navy Iron Man underwater quietly and then allow him to burst up from the water's surface and dispense justice on some modern pirates.

In conclusion...

Yes, we could expect something very similar to Iron Man in the next 3 to 15 years if we are willing to settle for the Iron Man Mark I suit.

The number of ways in which such a device could change the battlefield or dangerous police and emergency rescue operations is almost too many to list. We could also have versions of these suits in use at factories and manufacturing plants around the world. We would no longer need a forklift or dolly for simple yet heavy or tiring jobs, we would become the forklift. The benefits to workers on assembly lines would also be enormous as workers would get fatigued much less often and injuries from strains would be very uncommon.

Eventually technology will allow these suits to work without the human at all, but that is still a long ways off...

Or is it?

The physics of rapid deceleration of Iron Man's suit
Now if we could just ignore the physics of rapid deceleration...