How Iron Man's Suit Has Evolved Through the MCU

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Almost 13 years have passed since Tony Stark built his first Iron Man suit, since then, his suit, and the VFX used to create it, have changed tremendously. Both have advanced technically and visually in a kind of poetic synchronized evolution within both the Marvel Universe and our own. Like the music in this video?
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Mach 1.
In the first Iron Man film, Tony Stark builds an armored suit to enable him to escape from a cave. In 2008 the VFX industry was fairly advanced and capable of doing some incredible work, but because the director, and Hollywood in general, tends to have a fear of all things virtual, they opted for a practical Iron Man suit. Stan Winston Studio made a practical suit out of Aluminium, epoxy's, flexible urethane, and leather, all painted in the company's proprietary metallic chrome paint.
Weighing in at 90lbs the suit was too large and heavy for the actor and indeed his stunt double to easily move around in, so for the scene where stark exits the cave a CG suit had to be made.
The EmbassyVFX were given the task of creating the CG suit and thanks to the work from Stan Winston, they were able to measure and model their CG suit to the practical one. They even had some specific parts mailed to them to be able to copy the precise colors and textures.

Mach 2.
After escaping the cave, Stark gets home and builds an improved version of the suit, the Mach 2. For this suit, Stan Winston Studio also built a practical suit although it didn't actually appear fully assembled on film. ILM was tasked with creating the CG Mach 2 suit and (as did EmbassyVFX with the Mach 1) they used the practical suit to measure and model their virtual one. ILM had to pay special attention to starks surroundings because the Mach 2 suit is basically a mirror that reflects everything around it. When they showed the scene to the director he didn't know what parts of the suit were real and what parts were digital. As it turns out, it was all digital!

Mach 3.
The Mach 3 suit was similar to the Mach 2 in that it was a combination of both practical and virtual suits, but here, instead of trying to avoid the use of CGI, they began to embrace it, using it as a tool to make the suit better.
Again, Stan Winston made a practical suit, but this time the suit was made so individual parts could be put on or taken off, this gave the actor more freedom of movement in the action scenes. For a lot of shots, Robert Downey Jr wore only the helmet or shoulder pads, the rest of his body was covered in markers for motion capture.
ILM used its proprietary motion-capture system called IMOCAP, to collect Robert's movement data in order to animate the CG suit.
In the "Stark Expo" scene, no motion-capture suit was used, the CG suit was directly animated over the top of the tuxedoed Robert Downey Jr.
High-resolution photographs of the set and surroundings were taken to be used as reference material for the lighting of the CG suit, making sure the CG suit "sat" correctly in the original plate.

Mach 6.
The Mach 6 suit appeared in "The Avengers", and brought in a lot of visual and technological advancements. The Mach 6 had a rocket pack instead of hand thrusters, this free up the hands and meant that Stark could move easier in the air, but also meant that the VFX team had to add more complex rigging to animate the CG suit. In a scene that became known as "The Car Wash" scene, the VFX teams not only had to work out how the suit could be removed from Stark but also how its internal components would look and move. An asset had to be created for each component and each matched to Starks movement as he walked.
At the end of the film we see the Mach 7 suit, a suit that can be activated by a pair of bracelets, These bracelets would be the foundation for future suits.

Mach 42.
A big jump happened in Iron Man 3, Tony Stark creates over 30 different suits, a force he calls The Iron Legion. All these suits started from the original suit but the animators were given additional tools to allow them to alter the rigging on the fly, this meant that each Iron man suit could be made to move in a different way giving each one its own unique character. However, the rigging for the Mach 42 was by far the most complex, the script called for the suit to be used in everyday scenes such as sitting on a couch or giving a massage, this scene required the suit to move in complicated and subtle ways and the was no quick movement, smoke, fire, or explosions to hide behind.

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