This is one of the many extras on the Ultimate 2 Disc Edition DVD version of Iron Man. The running time is 1 hour and 49 minutes in total, and it's split into 7 parts. It is made up of clips of the film, interviews with cast and crew(they cover a number of subjects, and everyone has something to add), behind the scenes footage, drawings, pre-visualization, CG both finished and work-in-progress, sculpts, molds, and more.
The Journey Begins is 20 and a half minutes long. They talk about choosing the Granov's core design for the movie and building on that.
The Suit That Makes The Iron Man is 10 and a half minutes long. We see the physical suit worn by performers, developing of characters, practicing the flying on wires, etc. Downey Jr. actually talks about that 5 to 7 years after this, it would have to be mostly FX, not him actually wearing the armor – I couldn't tell you if he was right, but I'm not sure he expected back then to still be playing the role, now almost a decade later. I write this less than a week and a half away from seeing him in Spider-Man: Homecoming.
Walk of Destruction is 22 and a half minutes long. This one, of course, goes into the breaking out of the cave. It does also go into life inside of it, and the swanky life, the weapons test, etc. This is one of the places where we see how much more violent supporting characters were going to be with Tony before it was cut – Stane, where it's somewhat mutual, and, here, Yinsen.
Grounded in Reality is 14 and a half minutes long. It's about using actual military personnel and hardware, sometimes in frame, other times for basing developments of material. It also gets into stunts.
Beneath The Armor is 15 and a half minutes long. It goes into Peter Billingsley's cameo, using improvisation for dialog, the luxury within the villa, the climax, exhaustion, Las Vegas, and more.
It's All In The Details is 14 and a half minutes long. We're with them in the post-production suite, watching the nearly-done visual effects, sound work, and doing the last changes on them. The HUD is redone somewhat. Credits are created.
A Good Story, Well Told is 12 minutes long. The last parts of post. Meetings. Tie-in toys. Worries about whether it will do well in theaters. And we close at the premiere.
There is a little swearing, and though it's all bleeped, you can clearly tell what words were used. I recommend this to any fan of the movie. 8/10