While the Superman Returns suit was used throughout season 10 as a prop on the show, the shirt that Tom was wearing in the reveal is not actually the Brandon Routh suit. The Routh suit is incredibly snug and it didn’t fit Tom, who has a larger frame than Brandon. Production made a replica of the S shield and a new shirt for Tom to wear for that shot.
The Routh suit was worn by a photo double in the scene where you see Superman from behind, outside of Lois’ plane.

Costume Commentary
While the Superman Returns suit was used throughout season 10 as a prop on the show, the shirt that Tom was wearing in the reveal is not actually the Brandon Routh suit. The Routh suit is incredibly snug and it didn’t fit Tom, who has a larger frame than Brandon. Production made a replica of the S shield and a new shirt for Tom to wear for that shot.
The Routh suit was worn by a photo double in the scene where you see Superman from behind, outside of Lois’ plane.
Hm, okay, thank you. I’ve read some conflicting information on this, so I appreciate your input and will look a bit further into this at some point.
I worked on Smallville and was there during this time. I can guarantee that it’s true, but seeing as how you have no reason to trust what I say beyond me saying “This is what happened”, I totally understand your wanting to verify it 🙂
No, that’s verification enough for me. I appreciate you letting me know that. Up until you let me know you worked on the show, I had several videos and articles telling me different things – but if you came straight from the source, I will accept that. I’ll get the info on this page changed hopefully in the next few weeks. I appreciate your input.
Cool, glad to be of help 🙂