That 7th came out alright, obviously lot of details missing or things needing changed.
As for the problem with the armor sizing, yea even if someone makes armor and sells it, it will be tough to size it. We had that issue with two of our local Bo Katans, as KW who made the armor made them for a tall and busty female, so both our ladies struggled with having to get the kit to fit them, and that was for segmented armor bits. 7th Sister armor is nearly flush to the body and wraps around with no seam, it needs to essentially be made to the person's size and going to be hard to produce to sell. The girl who did the eva foam armor pictured has two open gaps/seams on the side of the armor, it looks like she just puts it on like a T-Shirt. For 501st that's not gonna work likely, those seams have to be almost nonexistant and will need to clasp together somehow. We are doing a prototype with eva foam right now to see what we can do, but also gonna try Sintra armor custom fit to us since waiting on someone to make armor will take a while, and the sizing is an issue with this particular costume.
We got our saber coming now so we plan on getting the saber parts done once we have it in hand for better sizing. The angle lines will not appear when printed, they are just where parts are attached, but will be seamless outside of where we want. General shape is done, just need to add in some detailing. The unique inscribing on the saber guard will likely have to be painted on by hand as it doesn't really look carved on. The 3D parts should be able to work with several types of sabers, we are doing only a single blade style on our but a double bladed style should fit fine.
We have also full designed the ID-9 seeker droids for printing. Plan is to have them poseable so we can have them on the 7th Sister like in the show. LED to be installed with a lense for the glowing red eyes.
We got the buckle and belt greebles done and printed, we got the gauntlet greeble in the works. We will post up the greebles for sale if folks are interested in them.