Here you can see a couple of upper leg forms resting atop these boxes.
The boxes are important - you'll see why in a minute. 

 
 

Here (below) are the forearm & elbow forms... and helmet front & back forms... 
The helmet form began life as an oil clay sculpture, was then molded and recast a few times until we got it right and then we finally cast this piece here to be used to make our true helmet master mold.

 

Now you get your two part urethane rubber compound ready, see all the white bottles and buckets? 

 

You suspend the master forms so that they hang down into the box - then you pour liquid rubber into the boxes. The armor forms are hollow so they want to float up out of the rubber, but we use bricks to weigh the forms down so that they stay immersed in the rubber while it cures. That big mold in the center is our biggest mold - the mold for a shoulder guard! 

 

Once the rubber sets you pull out the form and you have a rubber mold! 
This mold is for a vambrace (forearm guard). 

 
 

Now that we have our armor molds we can use expanding foam to make the actual armor pieces!

Here we see a foam helmet as it comes out of the mold. This particular photo comes from an earlier development stage, but this is what the actual pieces will look like when they come out of our new molds.