Love the model, it's looking great! Looking forward to seeing the final result; I've run across a couple Dead Space cosplays at Dragoncon and they are always so cool to see.
Yeah it's so tough to design a costume to be able to put it all on yourself. I got lucky with my ODST where I can put it on without help, but my brother's Spartan III requires a helper, so does his Star Wars Shore Trooper. My Winter Soldier costume definitely requires a second set of hands...
I know it's tough, but don't be discouraged when you have to start something over. My first helmet ended up way too big, had to pitch it and begin again. Cosplay is a time intensive hobby, but the end result is worth it!
Gotcha, yeah 60lbs of gear is quite a bit!
My current armor is foam, which is very lightweight, so I'll be curious to see how tiring a 3D printed suit is to wear all day at a con.