To make an intricate costume based off of a fictional character's suit of armor, I found a papercraft model of the character, scaled it to life-size, then print

To make an intricate costume based off of a fictional character's suit of armor, I found a papercraft model of the character, scaled it to life-size, then printed out the model in pieces at 1:1 scale at an office supply store using their large format printer. Bringing the huge sheets back home, I cut the shapes needed out of cosplay foam using the printed out segments as a template, then assembled the armor like it was a giant papercraft model. Worked great :) but to save time next time I need to account for foam having a greater thickness than paper. And maybe paint the foam before cutting it out.