Printing it out like that would sure be a lot faster than have to print, cut, fold, glue, resin, glass, bondo, paint. It would just be print, cut, fold, glue!! You could have the whole thing done in a few days!!
Some guy on Flickr took a photo of this cat on the streets on Halloween night last year. I had contacted the guy that snapped the shot initially to see if he could get me the creator's contact information. He told me that he didn't know him personally, but that the guy insisted that no one touch his costume. The guy that took the photo assumed it was made out of styrofoam. Just a little info for you guys to end the speculation on how durable his armor was...