When the folks at Tested wanted a real life Zoidberg costume from Futurama, they decided to work with effects artist Frank Ippolito to make it happen. He oversaw every part of the build from design to sculpting to molding to painting. Their Zoidberg even has some built in animatronics. Ippolito made a video with Tested and went over the process, and it gives helpful insight into how such a costume comes to life.
via Geeks Are Sexy