Here is the character, in various poses. The piece that is causing consternation is the arm, from the hand to just above the elbow: I fully acknowledge that this is an animated source, therefore physics and materials can be blended. I am looking for the best option to capture the source material's shape, appearance, and mobility. I would like the entire interior to be hollow. I was also considering doing just a half shell, with the bottom (the black) being spandex to help with ventilation. I will probably end up cutting it off just below the elbow, and making the elbow joint a separate piece, but first I wanted to pick your brains. -Foam: I think it would be too rigid, not to mention a pain in the butt to shape with all the curves. Am I wrong? -Cast Rubber: I think this would be too floppy, but I've only ever owned one piece in rubber. Would a higher shore rubber retain/regain neutral shape (e.g. pic #5) while still allowing enough flexibility for movement? -Rigid materials (sintra, Worbla, cast resin, etc.): As with the foam, I think the complex curves would be an issue. -Fabric: I was thinking of Spandex stretched over a foam skeleton, but I don't know how long that would last with such an extreme stretch. Are there any materials I'm missing that you all can suggest investigating? Or is there a material above that I am just looking at incorrectly?