He used to be an engineer for NASA before the incident, so he still had some days left until his security clearance expired, so he got some materials for his suit.

A fabric that can isolate extreme temperatures, he is still vulnerable to burning heat as a human, but can go thousands of degrees hotter.

An alloy that can stand thousands of metric tons of pressure. as he had to craft gauntlets that didn’t deform with his super strength.

Carbon fiber threads that could hold the fabric at the seams, A symbol on his chest that inspired the ideals of justice and freedom he withheld. He spent hours on end at the machinery to craft the perfect suit, one that would tell the common American citizen their protector has arrived and that Evil would be forever vanquished.

Then he looked to himself at the reflection in the window and realized he really looked stupid in his pajamas.