I have a fix for the Shapeways issue. theese are scaled at 54.9 mm across and fixes the thin wall issues.
Here are some pics of making the head shell and the final (Beta) costume:
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Thanks to everyone for their help and advice. I had alot of fun making this and can't wait to make it even better.
Does anyone happen to know the measurements of the web shooter? Whenever I open the file or try to have it 3D printed, the file is read as only being 2mm wide. :unsure
Thanks in advance.
EDIT: Never mind, I used the Shapeways link to scale the files back up to the correct size.