Here’s some relatively simple armor pieces I’ve made vac-form molds to reproduce quickly.

Gauntlets (forearms)

I made these simple molds with the removeable top box, so I can form left/right, top/bottom clamshell style gauntlets. They’re made with a lip on the inner edge where the two halves come together, so a steel u-track will hold them closed. I wear these with my custom mandalorian merc costume, with some LEDs and some fun details added.

I also have made this specific right arm gauntlet mold for Starkiller from the Force Unleashed video game. It’s made as close as possible to the specifications of the 501st Legion’s CRL. I use a clear plastic diffuser backlit with red LEDs and a black vinyl decal for the glowing display. Pictured below is one that I shipped, unfinished so that the person it was going to could determine the size when they assembled it.

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Female Chest Armor

I used a “Large” female mannequin torso to make this mold for forming female chest armor. I often use this form to create armor for Cobra’s Baroness character, but when cut properly, it can be turned into some shapely, attractive female Mandalorian armor. I also have a petite chest form.

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Knees/Shoulders

I like this mold because it can work for either knees or shoulders. I learned from my Biker Scout armor, that this shape, when used as knee armor, stays in place better than Boba Fett style knees. I already had the mold set up, which I had used to make Darth Vader shoulder armor for display bust.