There are a number of ways to do it. A very popular option is to make it out of paper and fiberglass it. Foam also works. I'm only 3d printing because that's what works for me.3d printing sounds great, but what if you cant, what can you use to build your armor?
Turns out I was a little over-ambitious. The print started having layer shifting about a third of the way through and I had to stop the print. I'm trying a new mk v file (the halo 4 version I think) split into four sections. It is printing a lot easier and with less supports, but I was hoping to have something that I wouldn't have to glue together at all. However, a piece is already done printing and it's coming out great. Not giving up on this four-year-old thread just yet!