Bring the worlds you love into reality
A father-and-son project that started in a Florida garage and grew into a dedicated US workshop. We thermoform cosplay armor kits for fans, by fans.
Bring the worlds we grew up loving into reality.
Xposed Designs was founded with a simple idea: bring the worlds we grew up loving into reality. What began as a father-and-son project in a Florida garage, driven by a shared passion for video games, film, and cosplay, has grown into a dedicated US workshop making high-quality thermoformed armor kits for fans, by fans.
Frustrated by the lack of durable, affordable, and truly customizable cosplay armor on the market, we set out to build something better. Every piece is made with the builder in mind, whether you are a seasoned cosplayer, a content creator, or someone stepping into the hobby for the first time.
Founder and Creator
Alex
Florida, USA
Led by Alex
Xposed Designs is led by Alex, a Florida-based creator, attorney, and lifelong fan of immersive storytelling through games and film. Combining a technical mindset with a passion for hands-on craftsmanship, Alex began developing thermoformed armor as a way to bridge the gap between affordability and quality in the cosplay space.
What started as small-scale experimentation quickly evolved into a growing business, with products now reaching customers across the world. Alex continues to oversee design, production, and brand direction, with a focus on innovation, durability, and staying true to the fan-driven roots that inspired the company in the first place.
Alex is recognized on the independent Fallout Wiki as a community content creator, and was a credited contributor to the 2025 Fallout Community Chronicles, a Fallout For Hope initiative. You can also find Xposed Designs at the Mojave Mayhem vendor booth.
Three Ways to Build
Raw
DIY vacuum-formed shell
Unassembled thermoformed ABS with all the rigidity and detail intact. Bring your own paint and hardware. The most flexible starting point for custom builds.
Assembled
Bolted hardware, strap set, ready to wear
Thermoformed shells joined with internal hardware, strapping, and closure systems. Unpainted so you can finish in any palette.
Painted
Hand-weathered, custom finish — assembled or unassembled
Available on both assembled and unassembled kits: hand-weathered with pre-war green, apocalypse metal, or desert khaki finishes. Delivered display-ready for conventions or shelves.
Thermoformed ABS
1.5 to 3mm, impact-resistant shell
EVA Foam
Closed-cell foam liner, weight-tuned
Acrylic Lens
With mirror film, tinted variants
Made in the USA
Every XPD kit is thermoformed, trimmed, assembled, and finished in our workshop. No overseas injection tooling, no drop-ship middlemen.
FOLLOW THE BUILD
What Wastelanders Say
“The weathering on my NCR Ranger kit looks like it survived the Divide. Fit is perfect, strap hardware is solid, and the lens clarity is spot on.”
“Bought the T-45D raw kit for a group build. Vacuum forming is crisp, panel fitment matches the reference, and support was fast when I had questions.”
“T-60 helmet with pre-war military green was shipped faster than I expected and looks better than the product photos. Hand finish, not mass-produced.”
Ready to Commission?
Have a specific faction, scale, or finish in mind? Start a custom order and we will get back to you within 1 to 3 business days with a quote.