I got a lot of people interested in my Robbie head/cosplay, so I am considering making some to sell. I am going to carve a solid block of insulation foam, smooth it out, and get a mold from it and cast it out of plastic (vents will be made). The size will be scaled down similar to the second photo of the Robbie head from Metal Gear for easy wear. The ears will be cast out of expandable foam and will most likely be removeable and able to ‘bounce’. I may even install fans in each and every head. You may choose any color for the head (I know he comes in pink, yellow, purple, blue, and white) and w/ or w/out blood.
These heads will actually look more accurate than my current once, too, including the blood.
So, what do you guys think? Questions? I am not sure what to charge (maybe a couple hundred), but it will definitely be cheaper than commissioning a mascot head from me. I am going to be working on the cast extremely soon.