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Iron Man comic book artist Adi Granov designed the Mark III with illustrator Phil Saunders. The Mark II resembles an airplane prototype, with visible flaps. A scale model was used for the shots of it being built.
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The animatronic required five operators for the arm, and was built on a gimbal to simulate walking. Stan Winston Studios built a 10-foot (3.0 m), 800-pound (360 kg) animatronic version of the Iron Monger suit. A single 90-pound (41 kg) version was built and was designed to only have its top half worn at times. It also foreshadows the design of Obadiah Stane's Iron Monger armor. The Mark I design was intended to look like it was built from spare parts: particularly, the back is less armored than the front, as Tony Stark would use his resources to make a forward attack. Stan Winston and his company were hired to build metal and rubber versions of the armors. Iron Man (2008) director Jon Favreau wanted the film to be believable by showing the eventual construction of the Mark III suit in its three stages.
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The Hall of Armor display at the 2012 San Diego Comic-Con, featuring the Marks I-VII (back) and Mark XLII (front)