The Didact in Halo 4 is the primary villain in the game. He has a highly detailed costume, but Evil FX Props & Armor managed to make it and started by sculpting the head, hands, and seemingly everything else from chavant clay. When he cast the hands, he used a hard urethane core covered with resin. Rare earth magnets were placed in the foam to hold the pieces of the hands together.
He incorporated electronics into the suit, too:
I used 2 types of spooled LED’s in the suit. The Helmet has a slightly lower output than the ones in the body to help with vision. Helmet LED’s are yellow tinted and waterproof. (colored to cast the proper glow from under the chin area and waterproof to keep sweat from shorting them out) The body uses the highest Lumen LED’s they carry and are Natural White. (the armor parts themselves were cast in tinted yellow SmoothCast 300 to give the proper color glow) In total the suit has about 650 LED’s, powered by 16 AA batteries total. (2 – 12v battery packs mounted in the back of the suit) For the dimming and strobe lighting effects I used simple, off the shelf, in line controllers.
See more photos of the build at Facebook and watch the Didact come together in the below video.