Captain America (Captain America and Avengers films), complete with a custom fiberglass shield for durability and screen accuracy. The Mjolnir prop was 3D printed, finished, and painted by hand to match the cinematic look, adding a powerful touch to this crossover costume.

Captain America (Infinity War version) – I personally weathered the costume to give it that rugged, battle-worn look just like in the movie. The Wakandan shields were 3D printed, sanded, and painted to match the worn vibranium finish seen on screen.

Star-Lord (Peter Quill) from Guardians of the Galaxy – The blasters were downloaded as 3D files, then printed, painted, and weathered by me to get that well-traveled, space-outlaw look.

Vulture costume from Spider-Man: Homecoming — built to capture the menacing look inspired by the movie’s design. Lots of effort went into making the mechanical parts look realistic and battle-ready. No, I did not (nor do I plan to) build the wings.

Just hanging out with your friendly neighborhood Spider-Man. No big deal—unless he tries to web up my gear again.

Early stages of my Cable (X-Men) cosplay. The arm was 3D printed in PLA, reinforced with fiberglass resin, then spray painted silver. I added a wash of watered-down black acrylic paint to bring out the details and give it a weathered, battle-worn look.

Full Cable arm and gun setup. The gun started as a wooden prototype I built with the intention of molding it, but after several failed attempts, I shifted gears. I ended up reverse-engineering the design digitally, modeling it on the computer and 3D printing it in sections for better detail and assembly.

Rocking my full Cable cosplay at DragonCon 2024! This was the first time I wore the complete build—including the arm and oversized blaster—all put together after months of work. Had a blast showing it off and getting stopped for photos.

Testing out some forced perspective tricks with my good friend Roger, who was cosplaying a Sentinel (from X-Men) during an X-Men-themed shoot we did at Fort Miley in San Francisco. Had a blast playing with scale to make the Sentinel look towering and menacing!

One of the cosplays I spent the most time assembling was The Punisher. This build pulls inspiration from several different versions of the character, mainly the classic comic appearances, the streaming series, and especially the 2004 adaptation of The Punisher starring Thomas Jane. I will admit I was pretty nervous about wearing this cosplay to a convention for the first time. Given today’s political climate, I wasn’t sure how people would react — especially since I chose the most controversial skull design, only because I genuinely love that version of the character and because, honestly, Thomas Jane absolutely nailed the role. Thankfully, my first outing in the cosplay ended up being an overwhelmingly positive experience. That reaction made all the time and effort I put into the build feel completely worth it.

This prop is one I'm actually the most proud of, because to make it cost me practically no money! I figured since Frank Castle is a Captain America fan (like myself) To me it would make sense for him to have his own defense frisbee. Initally I planned to recast my Captain America shield using a plaster mold, but because it was January and fiberglass resing takes longer to cure, that plan did not go over well... So I drove to the hardware store, grabbed a garbage can lid which I was able to get for free, since there were more lids than actual garbage cans. Gave it a base coat of black, painted a silver ring, and airbrushed the infamous skull in the center. Only took an hour to make.

One of my newest cosplays for 2026, Doctor Doom! I knew I had to have a Doom suit ready before Avengers: Doomsday hits theaters this year, and after going through the different versions of the character, I decided to base mine on the 2005 design from Fantastic Four. This cosplay also became something of a tribute to Julian McMahon, who passed right as I was about to begin work on this project, which gave the build even more personal meaning. The cosplay is set to make its official debut at Dragon Con 2026, and I’m incredibly excited to finally bring this version of Doctor Doom to life.

What’s a Doctor Doom cosplay without the iconic metal mask? For this build, I chose the 2005 helmet design from Fantastic Four for two reasons: first, it’s still my favorite live-action Doom mask design, and second, it was the version of Doctor Doom I grew up with and was first introduced to. This piece ended up being one of the most fun — and most challenging — parts of the entire cosplay. The helmet had a ton of fine details that needed extra attention, along with seams and gaps that required plenty of filling and cleanup work. And, of course, there was an unbelievable amount of sanding involved to get everything smooth and screen-accurate. It was also my first time building a two-part helmet, which made the project even more rewarding. I designed it with hidden magnet slots built into the shell, allowing the front and back halves to snap together securely while still being easy to take on and off. Seeing the pieces line up perfectly for the first time made all the effort worth it.

This is only a selection of the work I have done. Follow me on Instagram @pbuschinsta for more even cosplay builds, prop work, convention photos, behind-the-scenes progress, and all the projects that don’t always make it onto the website.