Thank you guys for all the input!!! I'm so happy to be rounding the home stretch on this lovely gal. And, yes, that's my girl, Jellybean, protecting my feet and keeping them warm while I work. xD As you can see she's terribly ferocious/vicious. Luuuuuulz.
So, the wrinkles at the side of the headpiece, just along the jawline, are actually a byproduct of using two different types of foam -- the softer foam wrinkles faster/worse than the stiffer foam especially in that high movement area. There's actually no visible seam, but it does wrinkle there after even just like one wear. I'm considering using the same type of foam for both pieces so I won't get that wrinkle.... but then I lose a lot of flexibility whereas right now I can turn my head fairly freely. So...... still workin' on it!
OK. Wore her to Wondercon.
Hoo boy. It was AMAZING, I MET ASHLEY ECKSTEIN (the voice actor for Ahsoka Tano). Holy crap and then the Nerdist tweeted my cosplay! Waugh so killer!!! OK. So. I don't have any professional pictures yet, getting ready for the con was sort of crazy, but here's how she's looking altogether:
And here's one of myself and my friend (wearing the "custom" headpiece):
Hoping to get some professional pictures done soon. Still need to weather and do some final detailing on the boots, and then it's on to the lightsabers!

I haven't 100% decided if I'm going to try and make a sculpt and mold/cast them myself or if I should just get them 3D printed. LOL Choices choices... I also don't like how this material is looking underneath the armor.... it's very... flat. I think I'm going to make a much more structured bodice, I think seams and the like will help distinguish it.
The chest and arms actually do light up, too, I just didn't bother using them at the con all day. xD