For my Ahsoka cosplay, I made her armor out of a several materials to get the look that I wanted. The base of each piece if made out of Sintra – a lightweight, incredibly sturdy plastic that is easy to shape with heat. I tend to prefer working with Sintra over Worbla because Sintra is a lot more durable and retains it’s shape for a lot longer. It’s a bit harder to work with though, so it did take quite a bit of practice to learn how to do some of the more complex shapes with it.
Once I had the basic shapes down, I used Terraflex for the details and additional layers. Terraflex is very, very similar to Worbla in almost every way, except it’s manufactured by Tandy Leather which I happen to live very close to! It’s great for detail work, and has a specific grainy texture to it once it’s been heated. Normally, you’d want to coat & sand that grainy texture away, but I really liked it for the “rough metal” appearance it gave the armor, so I kept the texture in!