Halo Armor New Building Materials and Techniques

[dmango]

Hey everyone!

In the live action series, Halo 4: Forward Unto Dawn, Master Chief's costume is made out of:
Undersuit: Foam Rubber (Most likely Latex Foam Rubber)
Helmat: Fiberglass
Armor Pieces: Self-Skinning PolyFoam Rubber

*Self skinning means that the surfaces of the armor are not porous like foam*

Legacy Effects Studios did an amazing job with the costumes and props, but I have some questions that I believe could be beneficial in terms of ways to make movable armor (a problem with rigid armor being limited range of motion).

How does a mold need to be made in order to make a cast out of Latex Foam Rubber, PolyFoam Rubber, etc.?

Where are these materials available?

Are there any particular type of paint that need to be used so that the foam is not dissolved?

Thanks Everyone!,
Dylan Mango

Resource(s):
http://http://www.youtube.com/watch?v=5gbAxuojePI

The Making of Halo: Reach "Deliver Hope":
http://www.youtube.com/watch?v=2Twj0_dLlbE

 

[Jason 078]

Are there any particular type of paint that need to be used so that the foam is not dissolved?

If you mix acrylic paint with some latex, you can get a good paint that won't split or crack when the armor flexes. I don't know the exact mix ratio, but my friend uses it for his N7 armor and has done full martial art rolls over his right arm without so much as a single crack.