Bumping this, since it's been a couple months. I'll echo the joy over the v3 files. I hope you've had a good summer and haven't stalled out on these. And, as much as I like the new helmet files, I'm curious where you are with the neck and chest-substrate files. I haven't seen mention of those in ages. I'll also echo a desire for hinges and mounts and such. I'd suggest a thin one-piece liner for the faceplate, so the faceplate can be printed in two parts, then bonded to the one-piece liner. That will solve any weakness issues, and also can be used to create a detailed interior (greeblies, eyeframes, mounting spots for padding, etc.) for the face, and can incorporate mounts for the hinge arms. The nice thing about th eidea of a liner is that it doesn't involve modding the existing v3 files any -- it would just be an addition, using the inner surface of the v3 faceplate as a starting point.
Hope to see more soon. You've been my greatest hope for a full, accurate v3 3D-printed suit since you started this thread. I'm in no rush, so take your time. I'm still over a year out from having access to a large-format DMLS printer (I'm hoping to be able to do it in titanium, but aluminum in a pinch), and having all the pistons and braces and support arms and bolts and other bits, all articulated, all interlocking... *happy sigh* I'll probably still start with the head anyway, though. *heh*
--Jonah