Meet the Maker: Alex Rennie
Bringing Characters to Life: Costume Maker Alex Rennie at Nova Labs
When Alex Rennie sees a character that captures his imagination, he asks himself one question: “Can I genuinely make this character come to life?” His answer has led to an impressive collection of costumes, each built from scratch.
Alex creates at Nova Labs, a community makerspace in Fairfax, Virginia. We asked him how he got started, what goes into his costumes, and how the people and tools at Nova Labs help him bring his ideas to life.
GETTING TO KNOW ALEX
Take us back to the first costume you made. What inspired you to start, and did you have any idea where it would lead?
My first costume was for a group attending MAGFest, a music and gaming
festival. Our theme was Over the Garden Wall, and the group unanimously chose
me to be the Beast—a tall, shadowy spirit who lives in the woods.
I had no costume-making experience, but as an artist, I wanted to meet my own
standards rather than buy something online. While researching how to make a
costume, I discovered Kamui Cosplay’s videos and templates, and I got started.
When you decide what to make next, what catches your imagination first? Is it a character, a song, a visual detail, or something else entirely?
The most important question for me is, “Can I genuinely make this character
come to life?” I usually know as soon as I see a design whether I can build it and
convincingly look like the character.
For this impressive Barnabas costume from Final Fantasy XVI, Alex created the entire look from scratch, transforming the character’s detailed armor into something he could actually wear. From the layered armor and intricate surface details to the helmet, gauntlets, and weapon, each element required careful planning, fabrication, and countless hours of hands-on work. The finished costume is a great example of how Alex combines creativity, craftsmanship, and problem-solving to bring a character from the screen into the real world.
Photo credit: @TylerHaunts
Which costume has been the biggest challenge?
I build all my costumes from scratch, and I take pride in knowing I made them.
The Nameless King has been my most challenging costume so far.
Some characters come from games, movies, or shows whose graphics leave details unclear. You have to interpret how things look and work, then make adjustments to bring them into the real world.
His hair is one of his most recognizable features, and I knew it needed to hold its
shape. Rather than rely on hairspray alone, I built a wig frame that would be as
sturdy as the rest of the costume.
What have you learned to do along the way? Did you come into this with a background in design or making, or did these costumes teach you the skills you needed?
I have an arts degree, but it had been years since I’d made something with my
hands. Most of what I know about costume making is self-taught.
Along the way, I’ve learned pattern making, sewing, sculpting, painting, wig
styling, laser cutting, mold making, airbrushing, costume special effects,
embroidery, soldering, and electronics. I’ve also learned to work with materials
such as EVA foam and Worbla.
Photo credit: @TylerHaunts
Alex brings the Nameless King from Dark Souls III to life in this completed costume, which he created and wears himself. From the detailed armor and layered clothing to the dramatic headpiece and oversized weapon, the finished piece shows how many different elements must come together to create a convincing character. Seeing Alex wearing the completed costume is the final step in the process—when months of designing, building, fitting, and refining finally become something he can step into and bring to life.
You’ve worn your creations to Coldplay shows. What is it like to bring something you spent so long making into that crowd? Is there a reaction you’ll never forget?
I’m not lying when I say people part like the Red Sea when they first see me in one of my cosplays! There’s definitely a shock-and-awe factor that I never get tired of. Some people just walk by, but I’ll almost always hear a “Holy sh*t!” or have someone run up and ask to take a photo with me.
Seeing those reactions after spending so much time creating a costume makes the whole experience even more rewarding.
Where does costume making fit into your life? Is it your work, a hobby, or something that has grown into more than either of those?
It’s a hobby—or, more precisely, my opportunity to make something completely from scratch and say, “This is mine, I made it.”
This work-in-progress Hollow Knight helmet gives a glimpse into Alex’s creative process before a costume is complete. Built piece by piece, the helmet is already taking shape, with the distinctive horns and layered details carefully formed and assembled. It’s a great example of the planning, precision, and patience that happen behind the scenes long before the finished costume makes its debut.
What has Nova Labs made possible for you? Is there a costume, a technique, or a moment of help from another maker that captures why you create there?
Nova Labs gives me the space and tools to make what I need. The people have
been great, too. They’ve taught me how to use new tools, shared techniques,
and offered advice on problems I would otherwise have been stuck on.
Before creating the final piece, Alex develops a fabric prototype to test the shape, fit, proportions, and construction of the costume. This stage gives him the opportunity to see how the different layers work together and make adjustments before moving on to the final materials. It’s an important part of turning an idea into a finished, wearable costume.
AWARDS
AnimeUSA , 2024
Journeyman (intermediate level) award, Magfest cosplay 2026
For Alex, seeing people pause in amazement at his costumes is exciting. “When I see
the smiles on people’s faces as they see my costume, it makes all the months of work
worthwhile,” he says. He also takes pride in the creativity, learning, and craftsmanship
involved in bringing each character to life.
At Nova Labs, Alex has access to the tools, space, and community of fellow makers he
needs to transform his next idea into something he can proudly say he made himself. Located in Fairfax, VA, just outside Washington, DC, Nova Labs is a membership-driven, all-volunteer makerspace, founded in 2011 with the purpose of empowering our community to Rediscover the Joy of Making Things! Current facility houses classrooms, workspace, incubator offices, and a shop that includes both common tools and advanced fabrication equipment. Members enjoy 24/7 access and help co-manage our space by teaching classes, maintaining equipment, and promoting making in the community. Nova Labs is a non-profit 501(c)(3) organization, supporting a wide range of open-source development projects that benefit both the local community and the world. Address: 3850 Jermantown Road, Fairfax, VA 22030
Who Should We Feature Next?
Each month, we’ll get to know one of our NOVA Labs members by asking a few questions about what they make, what inspires them, and what they’ve learned along the way.
Know someone whose work or story we should feature next? We’d love to hear from you! Send your suggestion to Veronika.Amaya@Nova-Labs.org or Slack: Veronika.Amaya.
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