This is my wife wearing the Thomas costume as she recently became a Daft Punk fan since their appearence in TRON movie.
Here i made the helmet using cardboard only (yes carboard, NO mache at all) with a new technique i developed to make perfect spheric surfaces with very thick cardboard. The gloves are my wife's work using thermoformed EVA.
The 80 leds were simulated using semi-transparent resin, there are only 10 ultra high intensity leds inside the helmet.
Now you can download all of the files needed to build it at [link]
everything is in there. Enjoy the papercraft.