I build suits. hardened foam, with opening faceplate, 3d printed hands and fingers, sound effect repulsors in the hands and walking sound effects in the boots
message me for details and pricing
To get a nice smooth finish, sand the print with 180 grit sand paper then use a spot putty filler then sand that with around 220 grit then undercoat then sand the undercoat with a wet and dry 800 grit and you'll get a perfect finish (well that's what i've found). For 3D files look up Dd3D...
I use 7mm foam for everything( helmet/chest/back/arms/abs/cod/legs/boots) 10mm is way to thick (in my experience)
Here's some pics of the Mk7 i built for a customer (below) just finishing a mk 6 at the moment