Hey, great question! I’ve used both, and while foam is lighter, it just doesn’t age well after multiple wears. DesignedBy3D’s builds completely changed my mind — their printed pieces are sturdy but surprisingly flexible when assembled properly. The detail is on another level too; you don’t lose texture or structure like foam tends to over time. I’ve been wearing one of their Destiny Cosplay costumes https://designedby3d.com/product-category/destiny for over a year, and it still looks brand new after a few conventions and shoots. The material resists cracking, and even with temperature changes, the form stays consistent. If you’re going for long-lasting armor that keeps its professional finish, 3D-printed is definitely the smarter investment.
