Little late to the party here, but I just wanted to say this information has been invaluable! I may never actually build one of these (not in Kryptonian shape lol) but these suits are incredibly beautiful and ingenius in their design, so having some new insight into their construction is intriguing.
Did have a few questions though, starting with a pattern. Could any unitard pattern potentially work? I see seams that start at the collar and run down to the armpits, and then from the waist to the groin... then of course the zipper in the back.
Also on the chainmail texture, if one were to go the DIY screen print route, forgive me for not knowing enough about the process, but how should one go about making sure there are no irregularities or can sp'ing be done with one huge body-sized frame? (I'm thinking in terms of several shirt sized frames.) Perhaps having a good sized stencil (made by a Cricut machine) and puff painting through that would be more practical? Just need to be very careful moving section by section...
There was a question regarding the under muscle layer, whether that was a lifecast of Mr. Cavill or sculpted. I have to assume it's the latter, while the overall design is relatively anatomical there are some shapes that aren't natural, rather they are exaggerated and kind of angular. My question though is are these muscles soft and flexible or hard like plastic? Again assuming, but it'd only make sense that they're rubbery, but other than a cold cast I don't know how one could achieve that metal shininess?