**** I NEED YOUR HELP ****
My plan is to 3D print all armor parts, then make molds of them, and finally to cast the final product in a polyurethane plastic. For some parts (abs, shins, shoulder straps, etc) the polyurethane plastic will have a hardness of 90A (basically the hardness of a skateboard wheel) but has an elasticity of ~80%. So it is much more durable than the 3D printed parts, and should not snap when I try to squeeze it over my chubby belly or stick my ankle through it. While other parts (helmet, shoulder bells, etc.) which do not need to flex and would be less prone to breaking will be made from a polyurethane plastic which has a 65D hardness and only ~10% elasticity.
*** Where you come in ***
What I need help with is making sure I am on the right track with things like scaling, dimensions, detailing, etc. Because I will be creating molds from the 3D parts, I want to make sure all the details are squared away before I start molding. If there is something that I need to change in the model, I hope to find out before I start molding parts.
Most of the armor will not be permanently affixed, as I will be tearing it back apart to create the molds. As an example, the abs are in 3 pieces temporarily held together with styrene and hot glue so that I can break them down into their components. Also things like suspension systems, attachment methods, final paint, etc. wont actually be done until the final parts are created.
So any help/feedback you can offer will be greatly appreciated.
Don’t mind the big nasty glue seam in the middle. This will be fixed before sanding and priming happens.