After a very long year of experimenting with metal casting techniques, I finally got perfect casts using the vacuum process. Now it's a matter of shotgunning all 300 parts of the exosuit using the same method, and then a few more months of finishing and painting.

The last problem turned out to be the lack of control over the mold burnout and baking process which is very crucial to obtaining quality. Ultravest instructions need to be followed to a T, especially the part where you hold it at 1350 F for two hours to ensure there is no water left in the mold, which otherwise turns into steam and destroys the metal surface.