Movie accurate replica of the iconic Ghostbusters Proton Pack
This project started with a single goal: turn up to a Halloween airsoft event in a Ghostbusters costume that stood out. Early Halloween games encouraged creativity, and fancy dress was part of the fun. A basic costume would have been easy, but once the idea of a proton pack entered my head, it escalated quickly. Rather than a rough visual prop, the aim shifted toward building something recognisably accurate to the original Ghostbusters packs.
The Ghostbusters fan community turned this into one of the most well-supported builds I have ever tackled. Detailed reference photos, measurements, wiring diagrams, paint guides, and even shopping lists already existed. I sourced a highly accurate 3D model set that broke the pack into manageable components, removing the need to redesign or rescale parts for the printer. Compared to many later projects, this felt structured and methodical.
Because three of us were attending the event, this became a small production run. Every component had to be printed three times, which highlighted early 3D printing realities. Failed prints, filament run-outs, bed adhesion issues, and heavy post-processing were common. Layer lines needed filling, sanding was constant, and superglue became a core material. PLA was used throughout, which proved sufficient given the cosmetic nature of the build.
Each pack used an Arduino-based controller running a community-developed sketch that handled lighting and sound effects. Power-up sequences, firing modes, and overheating behaviour were all pre-built and reliable. Large NiMH airsoft batteries powered the packs for an entire evening. All components were mounted to genuine ALICE frames sourced from the US, which made the packs heavy but comfortable to wear.
The packs were used during a night game as non-player characters and took knocks and BB hits without major failures. Scratches and scuffs added natural weathering. After the event, two packs were wall-mounted as display pieces and instantly became conversation starters. This project reinforced an ongoing tension I still manage today: knowing when a build needs to look good from 10 metres away, and when it demands obsessive movie accuracy.
