Hybrid Heads (3D printed & Foam)

Working on hybrid heads for up coming customers to create a cleaner look. My biggest issue with hard based heads are how heavy they can be or how they are not comfortable. I have been working on trying to solve the weight and comfort issue on my own heads. I have way more control when it comes to adding more details with 3D printed heads, aside that they glue like a dream (using PLA Light which prints like a hard foamie https://ninjatek.com/shop/colorfabb-pla/ ) and can easily be added to a foam back. So ideally I want to print the face where you can see in the diagram (the yellow) and create holes in the print itself to keep it light. Aside that it will print faster the head will be much lighter. Being able to do it this way will also allow me to give the option to wear glasses inside. The heads will not put any weight on your nose bridge which is a big reason glasses can easily be worn with these. I can make a variety of nose types which you could add on easily. So I can easily provide a nostril casted nose or even covered in fabric. I am working on a few nose molds to cast in resin to give the more shiny look/seamless look. The teeth I am wanting to cast in 2 parts, the gums being separate from the teeth. I can glue the teeth in after the gums are casted in whatever color is wanted. This way I can create a more permanent look for the teeth and add upper and lower teeth without adding much weight to the head itself. Since the head will be hollow it will be easy to add a fan for the ones wanting that added (I will only really add the fan for the ones going with the glossy eyes to prevent fogging) All other heads it would not be necessary. Since the front of the head would not be foam the head itself would dry a lot faster after it has been worn. I have put this material through the washing machine (the PLA light) and holds up extremely well so humidity will not be an issue neither will cleaning. As for eyes with the hard bases it will be very easy to secure the eye  and if the eye has been damaged over time it will make it a lot easier to repair as well (specially for 2D eyes). I am moving mostly to dye sub mesh over buckram for most suits, as it is is waterproof and plastic making it last longer. Plus dye sub is permanent so it work well specially for people that are harder on their suits. Head itself will be attached to a balaclava for comfort and to make it easier for me to attach the back of the head which I will make out of half inch foam. Ears will still be made out of anti fatigue matt (like a thick foamie) as it was worked extremely well over the years (light and durable, and the ears will not droop). Plan to create some registration marks on where the ears should go on the print itself to help me attach the ears on the head without worrying about it being crooked. As for the tongue it will still be similar to what I am doing now as it works well without adding weight. I do all my tongues out of mochi fabric and soft and stable as a backer. Gives the tongue that 3D look without looking too poofy. Since I am currently training and employee to be my head helper this will make it a lot faster/better to actually get through my commission list. We have a great system on working on paws, tails and bodies but still been too slow when it is just me on heads. Excited to see where all this goes but this is my plan.