The upcoming second season of Prime Video's 'Fallout' series continues to impress with its dedication to recreating the iconic post-apocalyptic world, largely through the use of elaborate props and practical effects. A central element of this immersive experience is the show's meticulously crafted power armor, a formidable symbol of the Brotherhood of Steel. Several cast members, including Aaron Moten, Kyle MacLachlan, and Walton Goggins, have donned these impressive suits and shared their unique, often challenging, experiences with Polygon in anticipation of the new season's launch.

Fallout Season 2: Unveiling the Realities of Power Armor

As the highly anticipated second season of 'Fallout' prepares for its debut on Prime Video on December 17, the cast members are offering a fascinating look behind the scenes, particularly regarding the renowned power armor. These imposing suits, a hallmark of the Brotherhood of Steel, are integral to the series' visual authenticity, yet they present considerable physical hurdles for the actors.

Aaron Moten, who portrays Brotherhood of Steel knight Maximus, described the armor as "heavy, heavy, heavy," estimating its weight at around 50 pounds for just the upper half. He emphasized the extreme difficulty and discomfort of wearing the suit, noting that merely getting in and out of it is a major challenge. Despite the physical strain, Moten acknowledged the undeniable sense of status and power the armor conveys, a theme frequently depicted within the show's narrative.

Kyle MacLachlan, cast as Vault 33 overseer Hank MacLean, humorously remarked on the armor's increasing weight between seasons, attributing it either to added modifications or his own aging. He described the experience as both "fun" and "crazy," highlighting the sensation of feeling genuinely powerful while encased in the suit. However, MacLachlan also confessed to the claustrophobic aspect, requiring assistance for even simple tasks like scratching his nose due to being "bolted" into the outfit, with no opportunities for bathroom breaks. Despite these inconveniences, he affirmed that wearing the armor was "definitely worth it" for the immersive feeling it provided.

Walton Goggins, who embodies both Cooper Howard and The Ghoul, found the power armor experience to be the most claustrophobic undertaking of his career. Initially underestimating the difficulty faced by his co-stars in the armor compared to his own extensive prosthetic makeup for The Ghoul, Goggins quickly realized his error. He recounted a severe panic attack after only 30 minutes in the suit, leading him to urgently demand its removal. He characterized the experience as intensely constricting and unenjoyable, a stark contrast to the grueling but manageable process of becoming The Ghoul, which takes two and a half hours for makeup application and lasts for 14-hour days on set. Goggins revealed that the prosthetics, along with the character's attire, entirely shape his portrayal of The Ghoul, influencing his movements and speech in a way that feels organic to the character rather than a conscious acting choice.

The second season of 'Fallout' will premiere on Prime Video on December 17, with new episodes releasing weekly on Wednesdays until February 4, 2026, promising viewers more of the compelling post-apocalyptic narrative and its distinctive, challenging visuals.

The candid revelations from the 'Fallout' cast underscore the profound commitment required to bring such an ambitious project to life. Their experiences with the power armor not only highlight the physical demands of acting but also emphasize the transformative power of practical effects in creating a truly immersive world. It's a testament to the dedication of the production team and the actors that they endure such discomfort to deliver an authentic portrayal, reminding us that behind every fantastical on-screen moment often lies a challenging, real-world endeavor.