Are you planning to mold the parts or use the 3d prints?
I want to stress that nothing on my suit is 3d printed or CNC'd
The helmet was sculpted from foam using Captain April's 2D post. I build an MDF skeleton and sculpted the helmet from bondo and pink foam.
https://c4.staticflickr.com/8/7472/26548752443_f41a248297_c.jpgDSC01854 by 2StoryProps, on Flickr
https://c1.staticflickr.com/8/7348/27120197296_7845b6d7a4_c.jpgDSC01855 by 2StoryProps, on Flickr
https://c3.staticflickr.com/9/8797/28424510522_5589bb2301_c.jpgDSC01882 by 2StoryProps, on Flickr
https://c2.staticflickr.com/9/8886/28452664321_f09ff9aaff_c.jpgDSC01892 by 2StoryProps, on Flickr
A mold of the rough sculpt was made and two casting pulled. One became the positive for the final helmet mold and one was made into the vacuum forming buck. The visor is 0.09" PETG pulled on our 24 x 24 inch protoformer.
This is just absolutely amazing!!!!!!!! I love the way you have done it. Helmets are like the "Holy Grail" for me because I have 0 skills for vacuforming or access to those materials, that's why when I see a piece of beauty like the it is always a *gasp* AMAZING!
Thank you very much!
- - - Updated - - -
Just a heads up. I had enough materials on hand that I was able to cast a new helmet. I will post a sale thread in the Junkyard tomorrow for it so keep an eye out if you are interested.