>>10910692
Real metal. Go hard or go home.

>>10910692
That looks awesome. Could try 3D printing. But as the other guy said, real metal reigns supreme.

>>10914578
fpbp

>>10916141
Should I use aluminum or some other metal?

>>10910692
Model them in Blender, turn them into pepakura models, then cut and build them out of cardboard or a shit ton of EVA foam. Balancing weight and durability is going to be a problem no matter what, but cardboard or EVA is your best bet. Even if they're completely hollow and made of the lightest material possible, they're going to feel heavy as fuck after a few hours at a con, so you'll want to be able to slip your arms in an out of them as easily as possible or else good luck eating, pissing, or opening doors.

cardboard and eva foam for breakable areas

>>10910692
Building them to a smaller more reasonable scale it will look 100% better and be easier to manage.

Nothing is worse than a Vi cosplayer with "accurate" gauntlets the size of their torso struggling to manuver, or a zabuza/cloud/guts with a cardboard abomination knocking ceiling tiles out of place.

Make it manageable it will look better, feel better, be easier to transport, easier to store and just overall be better.