I have seen a Batman HD Helmet fully completed and it looked amazing. never seen the full suit tho.
with some good Google searches you can find the file. Good Luck Bud.
Here is what I'm working on right now.
And I will be making Emile's Helmet and a HD Stormtrooper Helmet when I buy more ink for my printer maybe this weekend.
Let me know what you guys think, or if you have made one of those and would like to give me any tips.
Thanks guys.
check this out
http://www.google.com/search?q=bionicle%20pepakura&oe=utf-8&rls=org.mozilla:en-US:official&client=firefox-a&um=1&ie=UTF-8&tbm=isch&source=og&sa=N&hl=en&tab=wi&biw=1280&bih=676