I have a bunch of stuff like everyone else. There has been some members who vacuum form a lot of their small or mid-sized parts. this gave me an idea...what if you could vacuum form a helmet of some kind(EVA, MKVI, EOD, ECT.)
This goes for all helmets. This would be similar too molding, but this would involve slicing the helmet in half, and then making another half. let me know what you think...I might be on to something.
Vacuforming just about any armor piece is certainly possible. I've seen several vacuformed suits before. If you want to see some interesting stuff go to www.westerfieldstudios.com The guy who operates that business also is a mod here. He does all of his stuff by vacuforming.If you want to do it yourself, you would need to build a very cheap vacuforming table. You can search for, and find a tutorial on www.instructables.com If you want to do helmets, the main problem arises when you have to find a way to joing two pieces together. Kind of hard to do with two pieces of plastic that are very thin. But also keep in mind, that plenty of people have done it! So there's always a way
Look at the thread in the noob forum called "Griffin's New Smooth Helmet!", in the first post they show their vacuum formed star wars helmet.
Have no idea how that stuff works but it looks like he did it!