Midwest Cosplay and Duct Tape
Welcome back to our Cosplayer Spotlight series, where passion, creativity, and fandom collide. Today, we’re diving into the world of Brad “Duct-Tape” Hale — a veteran cosplayer, prop maker, photographer, and all-around creative force. From his first convention in 2005 to building show-stopping costumes and even meeting his wife through cosplay, Brad has spent nearly two decades shaping and celebrating the community. Let’s get to know him!
Quick Background Questions (Fast Facts)
What is your full name (or the name you go by in the cosplay community)?
Brad: My full name is Brad Hale.
Where were you born?
Brad: I was born in a little town called Galesburg, IL.
Where do you currently live?
Brad: I currently live in Chicago, IL.
How old are you (optional, if you’re comfortable sharing)?
Brad: My age is 42.
What is your primary occupation (outside of cosplay, if any)?
Brad: Outside of cosplay I’m a Spl-Project manager for a property management company. I also work as a freelance photographer, prop master (various indie film projects), and a content creator on YouTube for 10 years.
When did you first start cosplaying (year)?
Brad: I started cosplay casually back in 2005 with ACEN as my first convention. Professionally was around 2009.
What was your very first cosplay character?
Brad: My first cosplay was “Eriks” from Trigun.
Childhood & Early Creativity
As a kid, were you into comics, anime, video games, or something else? Which ones influenced you most?
Brad: I was an 80s kid and loved all the classics like Transformers, TMNT, and Star Wars. Then the 90s started my love for anime, Marvel, and DC all at once with a blast of amazing cartoons.
Did you make things or perform as a kid (crafts, theater, art, etc.)?
Brad: As for crafty/performing as a kid, my mother felt theatre was good for me at a young age. I ended up liking it so much, I did theatre all the way through college. Cosplay to me was such a growth of theatre in public that I fell in love with it as well. I’ve also been an avid painter for years and built it into my prop work.
Were there any characters or series you were obsessed with growing up that pushed you toward cosplay?
Brad: Shows that shaped me for who I am now… I’d have to say Power Rangers definitely started my hero love, especially Tommy Oliver. Started out bad, chose good, and grew to be the leader he could be. But it also kindled my love of wanting to make cool items I saw on TV or in movies, i.e., prop work. Jump 30 years later and I’m working on multiple cool projects due to my prop work.
Cosplay Journey & Motivation
What inspired you to try cosplay in the first place?
Brad: My inspiration for cosplay was simple. I love Halloween and dressing up. It wasn’t until late high school/early college that I heard about conventions. But one 2005 ACEN weekend I attended my first con and haven’t looked back since.
How did your first cosplay experience go?
Brad: My first exp of cosplay wasn’t bad, the worst thing was getting lost using MapQuest printed directions.
What do you personally get out of cosplay—creatively, socially, emotionally?
Brad: I come back to cosplay for a variety of things. First off, it’s loads of fun and a creative expression outlet for a good lot of people. All the cosplayers, voice actors, and staffers I’ve made friends with over the years are always a good reason to go back and visit with old friends. The adventures I’ve had at these events bring me back every time.
Do you build/make your own costumes, modify them, or commission others?
Brad: Do I make my own outfits/cosplay? That would be a yes and no. I make most of my normal cosplays and large bulk costumes, but I love supporting my artist buds commissioning items like leather work, certain casts, and so forth. I try to learn what I can and grow from that crafting-wise. But there are always some things we can’t make at the moment or just don’t have the tools to make at hand. So commissions ahoy and supporting fellow creators.
How long does it usually take you to put a full look together?
Brad: How quickly can I put a cosplay together? If it’s one of my casual outfits, 10–20 minutes. Bulky or accessories-heavy costumes, 30+.
Conventions & Community
What was your first convention? What do you remember most about it?
Brad: My first con, ACEN 2005, was a wonderful exp. I spent most of that Saturday just enjoying the dealer’s hall and all the cool costumes everywhere. So many photos were taken and it inspired me to want to create so much. I was so much in my element I knew I was home.
What are your favorite conventions to attend, and why?
Brad: Favorite con to attend and why: PMC–Power Morpicon. PMC is the largest Ranger/Sentai con and it’s a blast. Collectors’ heaven and full seasons of guests there to meet. It has the best guest list I’ve seen next to SAC-Anime. PMC.
Do you mostly attend as a fan, or do you also do panels, competitions, or guest appearances?
Brad: I’ve been honored to be a guest at multiple cons over the years and host so many fun panels. I love doing guest relations at times and consulting for VAs. But nothing beats a relaxing convention weekend meeting guests in cosplay as an attendee.
What do you think makes the cosplay community unique compared to other fan circles?
Brad: The cosplay community stands out to me for the reason they made me love it. The pure passion of art, character, and creativity make it such an experience. Finding others dressed as you in a similar fashion or fandom is always a refreshing weekend.
Have you formed lasting friendships or collaborations through conventions?
Brad: Did I make lasting friends in cosplay? Yes, I have. So many friends across so many cons. I’ve even made some fun professional actor friendships over the years. You could say I’m talking with one as we speak. But most importantly, I met my wife through cosplay and conventions.
Favorite Characters & Styles
Which cosplay is your personal favorite so far, and why?
Brad: My favorite character to cosplay? I’d have to say it varies at times over 20 years. Some of my favs are Freddy Fazbear, Mr. X, Eva Unit 1, and Stardust Dragon.
Are there any dream cosplays you haven’t done yet but want to?
Brad: Dream cosplay would be full MMPR Evil Green Ranger with Sword of Darkness.
Which character do people recognize you for the most?
Brad: I get the most recognition from my Arin Hanson cosplay (EgoRaptor–GameGrumps) and Mr. X (RE2).
Do you prefer anime, video game, comic, or original character cosplays—or a mix?
Brad: I lean into a mix of anime, sci-fi, and games.
Memorable Experiences
What’s the most memorable moment you’ve had while in cosplay?
Brad: Most memorable exp I had was definitely being a guest at Youmacon. It was a sobering moment and both fulfilling at the same time. A mainstream convention I first attended as an attendee only to years later walk around as a guest.
Have you ever had a particularly funny or awkward interaction while cosplaying?
Brad: Halloween one year I was dressed as “Demon Dean Winchester” with full sclera contacts (solid black eyes) and it literally scared the Burger King employee taking my order. I was in such a rush that morning to get ready for events, I forgot I was wearing them.
Any wild or unexpected challenges you’ve faced in costume (wardrobe malfunctions, travel issues, etc.)?
Brad: Biggest cosplay challenge is my shoe size. Size 15/16 makes cosplay shoes hard to work with.
Perspective & Advice
How do you see cosplay evolving in the next few years?
Brad: I would love cosplay to grow into a big and loveable community. It’s grown in the 20 years I’ve been here and I’m all for the cool cosplay tech advancements. I’m from the day and age of using plastic buckets to build costumes. Now you can just order resin, PLA, EVA, or the straight-up premade outfits.
Do you feel social media has changed cosplay (for better or worse)?
Brad: Social media helped saturate and grow cosplay. But I’m afraid it’s turned into a $ machine that keeps making new cosplayers think they have to do so much instead of having fun.
What advice would you give to someone brand new to cosplay?
Brad: Best new cosplayer advice I’d give is: have fun, breathe, and slap on a good pair of shoes. Go light your first con, see how others do their stuff, and take notes. Most certainly you should break in your cosplay/shoes to save you misery and blisters.
What’s the biggest misconception people outside the cosplay world have about it?
Brad: Biggest misconception for cosplayers: that it’s a loser’s hobby labeled as “weird” or cringy. Yet every normie can’t not go nuts when a celeb cosplays for a party, but then dogs on their friend, co-worker, or family member that says they also cosplay. They can get bent, their loss.
Closing Questions
Where can people follow your work (socials, website, Patreon, etc.)?
Brad: Fans can follow me at Brad Duct-Tape Hale YouTube/Insta/TikTok.
What’s your next event or big cosplay project?
Brad: My next big event is Resurrection (4pt mini series) finished filming and should release Q1/Q2 2026 (Prop Master).
Anything else you’d like fans or readers to know about you?
Brad: I’m just an older nerd collector having fun as life goes by. I love cosplay, creating, and making people smile. Work hard and strive for your goals. “Be like duct tape, stick to it.”
That’s a Wrap!
What an inspiring journey! Brad shows us that cosplay isn’t just about costumes — it’s about friendships, artistry, and sticking to your passions (quite literally, in his case). Until next time! And if you’d like to explore cosplay’s cultural impact further, check out resources like BBC Culture.
