I'm working on a robotic mohawk, which perches atop the wearer's head and responds to their brainwaves. This calls for a rigid "headspine" to hold the movable spikes in place.
My first iteration was built from yarn-wrapped armature wire and nylon tubing, to support the actuation mechanism I was planning at the time: a servo pulling fishing line back and forth to move the connected spikes. While that didn't work well enough, it was easily molded and held its shape. This came in handy when I decided to 3d-print the next version.
What do we need?
This method employs a Wacom Bamboo drawing tablet and Autodesk's Fusion 360 software (free for non-commercial use). The intermediate step was done in Adobe Photoshop and Illustrator, although you could also use open-source software like Inkscape -- anything that will produce an SVG.
Why do it this way?
I thought this would be a relatively quick and easy way to transfer my head-shape to a 3D modeling application, without enlisting someone else to scan my head. Besides, it's better to use a physical reference than a visual profile of your head, which is distorted by hair. Since I already have a mohawk, modeling from photos wouldn't capture the underlying shape I needed to fit.