I havent made of sold them in years but use to run kits for "do it yourself builders" at $1,300  just I only made a hand full of full suit kits

About 350°F for 7 minutes generally

yeah as long as you need a hollow form pretty much vacuum forming is the ideal option.

I use too, haven't made in any quite some time not sure of the material cost at the moment the price of oil depends on the prices of plastics required.

Using Pepakura is cheating, THIS is the master stuff.

I dont think it

depends on the material what type of plastic and how many sheets it takes like 6 runs on the machine for a full iron man suit as an example.

I made a outer press mold I push into the eyes to compress them deeper and sharper just gotta do it while the plastic is still hot.

Well alot a universities have vacuum forming machines on hand that's were the machine I use came from was a 40 year old broken machine that was given to my grandfather and a few years back I found it in storage fixed it up and started using it.