A lot of costumes can depend on budget, you maybe aware at this point that none are cheap!, the only time I have seen ones that can be cheaper would be members selling or changing costumes., bargains can sometimes be had, we have a sales area here where sometimes costumes can be found here:- https://www.irelandlegions.com/forums/index.php?/forum/26-junkyard-for-saletrade/
If you went for something like a 'Original trilogy Stormtrooper' or 'TK' , we can point you in the right direction, we know quite a few reputable vendors that make them in the same way as the originals, vacuum formed abs plastic (ready build or in kit form), Stormtroopers are always a great choice, they get plenty of attention, then again I am slightly biased in this regard????
As far as '3d printed costumes vs vac form' I generally lean towards vac if it was available, I put together a 3d print death trooper once and it was an epic amount of sanding, priming, painting etc etc, then there is the practicality of the costumes for wearing at events, vac form is nice and light, this is just my experience though and really depends on what you plan to do with the costume once completed.
For Mandalorians I would check out the detachment for the best info on this:- https://mandalorianmercs.org/ , are you referring to real metal aluminium casting, or using resin and aluminium power to cold cast in resin?, I don't have experience with real metal casting but have some experience with resin casting small props.
I best advice I can give is to go for the costume/s that interests you the most then start a 'build thread', this can be very useful, members will chime in with tips and advice to help.
If you want us to move or split this topic here:- https://www.irelandlegions.com/forums/index.php?/forum/19-propscostumes-discussions-questions/ we can no problem, or just leave it here and start a new thread ????
*Yeah PC's look a lot less intimidating that they used to be to build! lol
