saw your comment on my blog zemjw, which was VERY helpful. I hadn't considered just 3D printing everything I'd need. The individual heads were coming in at 3.50 each in Frosted Ultra Detail. I need four copies of each visor head, and 20 copies of the mask/helmet. (40 total heads x 3.50 is getting a bit pricey). I was hoping to get it down to about a 1.00 each, which I thought home casting in resin might do.
I'll modify the sprue and upload to Shapeways, but wanted to get some input on considerations I have to make in the sculpt/positioning. If the numbers don't work out I might see if I can get them cast in metal by a pro. The cost increase might be worth it to skip the hassle of home casting.
Thanks so much for your continued feedback, it's been a big help.