Without a doubt superhero movies are my favorite, and Iron Man is my favorite hero. That made this one of the harder assignments for me. The physics in the movie weren’t too bad. Most things were based on the same laws we have to deal with in our world. Apparently the movie world has a car with a drive train that shifts from rear to front wheel drive and has a bumper and quarter panels that are directly connected to the frame of the car. (Watch the car that Stane throws at Stark during their battle on the street.) They also seem to have no requirements for crash testing their Hydrogen powered buses. (Watch how flimsy the sides are) Other than that once you get past the idea of a flying suit of amor the rest pretty much makes sense and fall into place.
How does it work?
Super Strength.
This power is a must because the complete setup (man and armor) weighs 425 pounds minimum, more based on armor configurations. Tony has to be able to move in the armor with speed and grace so hydraulics are out of the question. The tubes shown in the movie are fiber optic conduits and temperature regulation arrays. The ARC reactor provides the power to the repulsor tech. Perhaps Iron Man doesn’t so much lift things but uses magnetic fields to push them away. In this way he could deliver a devastating punch by changing the polarity of various armor parts (fist and shoulder) to make the repel each other. The reactor power seems to be virtually unlimited so the magnetic fields wouldn’t have to be limited to a certain size. It would also explain why cars picked up by the bumper don’t fall apart. Of course it would take a lot of computing power to constantly adjust all those parameters, but we are already doing it with the latest generation of fighter planes (F-16, F-18, F-22, & F-35), and we all know Tony Stark is much smarter than we are. So by using electricity and magnetism Iron Man can move and perform great feats of strength. Try not to think about how he lifts large boulders or other nonmagnetic things. There must also be a lot of shielding in the armor because that amount of electromagnetic energy would surely disable the on board computers required to run the suit.
Damage Resistance.
While Stark is just a regular man the armor is invulnerable (or close to it). If the laws of physics were really in force then he would be turned to a liquefied paste inside the armor. The forces he experiences while flying ( high G maneuvers), impact from artillery and missiles, along with the fists, feet, and falls that are a part of life as Iron Man should still be felt by the man inside the armor. Inertia still has to be dealt with along with momentum. The affects of small arms fire through some types of artillery could be reduced through the use of repulsor technology. An electromagnetic field could be used to slow the projectile and reduce its momentum prior to impact. Another option is to use an electric reactive armor technique. You can read about it here: http://en.wikipedia.org/wiki/Reactive_armor#Electric_reactive_armour That may also explain why there is a layer of armor under the red and gold layers. When the armor decelerates from supersonic speed to a dead stop the body inside wants to keep going. Internal organs should hemorrhage and death should occur. That’s why the armor employs the same inertial dampeners used on Star Trek.
Flight.
How does Iron Man fly? Since there are no flames or heat coming from the boots they must use the same repulsor technology as the hand units. The question is what are they repelling? I can understand them working in the test lab but not in the open sky. What do they push against to provide propulsion? Maybe they just push air out with great force but you never see any intakes for air. You do in the comics but not in the movie. At best he should be able to hover like in the test lab or launch himself like a cannonball. Even that would depend on the strength of the platform he was launching from. It could be that he interacts with the electromagnetic field of the planet itself to achieve flight. This is one we just have to press the “I believe” button for.
So as you can see with the exception of flight all these powers are easily explainable. Much of the technology is already being used or tested. (on a much smaller scale in most cases) All we need now is a 12 Gigawatt ARC reactor and an inertial dampener and I’m on my way… Hey, it could happen!

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