I used a new to me material – a flexible putty foam. I wanted to see what it could do. So Xena’s armor is made from that.

 

It was sculpted in oil clay then molded in a porous clay and cast from there, giving the putty foam an instant warn, pitted look. 

 

Xena was a plus size costume and doing a fitted princess cut in leather had some challenges but it all worked out really well.