Helmets and other costume parts for Collegehumor "Troopers, Rise of the Budget"

This was a fun project. I was tasked with making the trooper helmets, Dread Lord helmet, 3 Middle Management bot costumes and a set of android arms for one of the characters to wear. (I'll post photos as I find them) Not huge budget or time. The helmets and the robot costumes were quickly concepted in zbrush. Yes, they're silly. trust me, I know. They were VERY specific about the look matching some extremely rudimentary concept drawing.
After they were happy with the 3d versions, I broke them up for printing and started creating the physical patterns.
I hired my brother to help me clean up the 3d prints and cast and paint the copies after I made the molds.
I would have liked all of the helmets to be gloss clear coated but they wanted a matte finish to make green screen work easier
The Middle Management Bots, and robot arms (not shown here yet) were foam fabricated.
For the bots I used templates created from the zbrush mockup of the robots then exported to Pepakura creator, which was very handy. The eye assembly was modeled in Fusion 360 and 3d printed.
On a personal note, this was my first project using zbrush and not exporting to other software before printing, which saved some steps and that was pretty exciting thing for me.
I'll add more photos here as I find them and some zbush images of the parts breakdown if that's interesting to anyone.