I'm using a 3D printer for the rough forms of the body; these are then modeled upon with light weight car filler, epoxy putty and putty filler - with lots of sanding. Plasticard / HIPS is used for some of the more detailed parts. The 'rubber' between the armoured plates is modeled using aluminium or thick solder wire. Once all this is done the hard armour is going to be moulded and cast in resin with the rubber in betweens done in silicone or possibly urethane rubber, with a fully poseable armature; so this is only the master model hence no pose. I'll be able to make a few of them; they're basically going to be like huge action figures but ultra detailed. I'm lucky I used to work in SFX / Stop motion animation so I've got a fair bit of experience with that sort of stuff especially making large puppets.
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