Real-Life Tony Stark: Engineer Builds Working Iron Man Suit Powered by Tesla Batteries

Image: Collected

A Russian engineer and YouTuber has brought one of Marvel’s most iconic fantasies a step closer to reality — constructing a functional Iron Man-inspired suit powered in part by Tesla battery cells.

Alex Burkan spent roughly six years crafting the wearable armor from scratch in his garage workshop. The suit features 3D-printed metallic plating, a detailed helmet, artificial muscles, sensors, and a custom power system. At its core are 18650 battery cells sourced from Tesla vehicles, combined with a hydrogen electrolyzer that splits water into hydrogen and oxygen. This gas mixture fuels a hand-mounted “repulsor” device capable of producing visible thrust and enough force to push the wearer backward during tests.​

Whatsthejam

Burkan has meticulously documented the entire process on YouTube, from early sketches and clay models to advanced fabrication techniques involving composites, carbon fiber, and Kevlar. The project has drawn comparisons to Tony Stark’s famous line about building the original suit “in a cave with a box of scraps,” a sentiment echoed across social media as footage of the build and testing circulated widely.​

@complex

While the suit is not a full flying, invulnerable superhero armor, it represents an impressive feat of DIY engineering — a working prototype with powered systems, a functional blaster mechanism, and wearable structure that has captivated hundreds of thousands of viewers. Burkan continues refining the design, including upgrades to the hydrogen reactor system meant to mimic the comic-book arc reactor.

The recent viral clips shared by accounts like Complex have once again put Burkan’s long-running project in the spotlight, reminding fans that with enough determination (and a few Tesla battery packs), even comic-book dreams can start taking physical form.