I bet someone would make a fortune if they made a run of the eyes like on the costume in post #8. And I bet they wouldn't be hart to make out of craft foam or something.
If the interest is there, I'll gladly make a set and offer them in black onyx (plastic) or black urethane (rubber). I just don't want to go end up making a mold that never gets used.
A quick sketch to estimate the proportions. I was thinking 10cm x 14cm. And they look quite thin, probably only 3mm or so. Sound about right?

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