My Crusader from Diablo 3 is made out of foam
and a thermoplastic material called "Worbla's Finest Art".
The horns are sculpted with clay, then I made a two-part silicone mold and casted them with liquid plastic.
I used an airbrush and acrylic paint for the paint job,
for the weathering I used acrylic paint, too.
All in all it takes about 300 hours to build this costume.
This was my first big armor project! All patterns are selfmade.
"Funfact": The flail weighs about 20kg and I carried it with one hand the whole day. Good workout!
For progress photos take a look on my fb page: https://www.facebook.com/pg/Liika.Cosplay/photos/?tab=album&album_id=707072252694146