If what you say is true, then the vacuform bucks, if created by Ainsworth for purposes of vacuforming the helmet componenets, might also be considered a work of art and be considered Ainsworth's work. He may still be in the clear at the end of the day.
Bottom line is, LFL can appeal this over and over and do far more damage to Ainsworth in legal fees. They can ultimately bankrupt the guy just by pursuing this forever and ever. He should have been more careful about poking the tiger with the stick so to speak.
From what I've gathered AA was supplied with the forms to make the helmets and the armour. Any copyright in them vests with LFL. Even if he created them and copyright attaches to them, the copyright would be assigned to LFL by operation of law.
They can appeal it again, but only on a point of law. The only real issue here is the interpretation of "artistic craftsmanship" which is what this appeal is based on. If LFL win it'll likely be the end of it due to the cost of AA starting an appeal.
If LFL lose they'll likely take it to the UK Supreme Court. If they lose there that is the end of the matter at least in the UK.
On the costs issue, in England the general rule is the loser pays the winner's costs. It isn't quite that simple, but it is a good starting point. We also don't know how the litigation was funded. It is entirely possible the costs are not coming out of AA's own pocket. It is possible he has insurance or some other arrangement which will cover his litigation expenses.
All of this is speculation, and I have no idea which way the decision will go. It'll be an interesting judgment to read, if you like that sort of thing.