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A series of serious questions taking on a serious project

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Hey guys so i will be back at building again,
i am taking on roughly 6 suit builds to be completed about September i would like to be done in Aug but its not realistic.
I am a bit perplexed as to the build method i am going to take. Before hand i have extensive arts and sculpting skills.
i will be doing 2 adult size iron man builds Mark not decided yet and 1 child size
then 2 adult cog armor and 1 child size.
i am leaning more towards a foam build then casting...here is where the dilemma comes in, i would really really like to NOT use anything toxic as i will be in my condo complex indoors building. i have a spot i can paint at no issues. so if i do decided to mold and cast ei how xrobots did what resin can i use to reinforce the rigid suits. and how well will it work.
second approach would be to take the"High impact urethane" LOL Sorry i had to) plastic approach. for the iron man armors. im a bit torn, and as far as the weapon props for the cog armor i plan to run casts on them as well.
i will begin this month just looking to be pushed in the right direction, i what nothing but time for this, i am my own boss and 25. so please please let me know what you guys think
i will be making a thread of the builds as well on here
Thank you all in advance

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