Here’s a costume I built for my son for Halloween. It’s made of EVA foam. I used Pepakura and the videos from the awesome TheHeroTutorials videos on YouTube put up by user Stealth from the RPF forums. The design files came from user unheard on www.405th.com. Many, many, many thanks to these two individuals for their videos and design work.
Here’s a video of the voice-to-led function that lights up the mouth piece when he talks.
And here are some pictures: