The Batsuit: From heroes to villains, the costumes have been an integral part of bringing the characters of the Dark Knight trilogy to life, starting, of course, with the indelible silhouette of ... more 
The Batsuit: From heroes to villains, the costumes have been an integral part of bringing the characters of the Dark Knight trilogy to life, starting, of course, with the indelible silhouette of Batman. Following ‘Batman Begins’ the Batsuit was significantly redesigned for “The Dark Knight,” resulting in improved comfort and flexibility, especially in the neck and shoulders. As the saying goes, ‘If it ain’t broke, don’t fix it’ so costume designer Lindy Hemming and her team made no changes to the suit for ‘The Dark Knight Rises’. The multi-layered Batsuit was comprised of 110 separate pieces, each of which had to be replicated dozens of times over the course of the production. The base layer was made of a polyester mesh that is utilized by the military and high-tech sports manufacturers because of its breathability and moisture-wicking properties. Individually molded pieces of flexible urethane were then attached to the mesh, forming the overall body armor plating. Adding another level of protection, light but strong carbon fiber panels were placed inside the sections on the legs, chest and abdomen. The cowl was sculpted from a cast of Bale’s face and head and then molded for a perfect fit. There were also ten different versions of the iconic cape, ranging in length and shape—from shorter ones, used in action scenes, to the glider cape that snaps into the shape of spread batwings. less 
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Tue, Jul 17, 2012 8:00 PM AST (Arabian)