Kind of off the topic or maybe a “no no” question. But do you have any idea if anything ever came of that other 343 fella Unyshek asking for input from the community? I don’t remember ever seeing anything else about it.
Yes, all my undersuit parts are cast. For my H3 ab-wrap mold, I simply created it out of EVA craft foam, built up the edges, applied a release agent, then poured rondo to make the mold. Once it cured, I removed the EVA craft foam, and now just pour a couple layers of tinted mask latex followed up with a layer of Lycra to give it strength. Overall, it was a really simple process to create Here is a video of me demolding one of the wraps for reference.