About Foxhead Workshop

I’m Geoff. My professional background is in software, including enterprise architecture and systems design. Cosplay gave me a reason to take those skills out of the terminal.

What started as a screen-inspired Din Djarin build turned into something much larger. I’m still building it. Getting this far has meant learning 3D modeling, mechanical design, embedded systems, microelectronics, finishing, and fabrication: everything between a digital model and a part you can actually wear.

Foxhead Workshop is a small, family-owned shop, and we’re growing. Mandalorian armor is where it started and where the focus still sits, but the workshop isn’t fixed to a single fandom. The catalog grows as each build wraps.

Projects such as the Whistling Birds and the Mandoputer sit at the intersection of firmware, electronics, mechanical design, and prop work. They have to look right, work consistently, and survive a convention floor.

What we make today

Whatever your budget or skill level, there's a way in:

• Templates & build guides — STL files and the step-by-step finishing guides we've written for our own builds.
• Raw 3D-printed parts — high-quality PETG, ready for builder finishing. Available in size variants Small (95%), Standard (100%), Large (105%), and XL (110%).
• DIY hardware kits — modular electronics like the gauntlet darts kit (12 individually addressable RGB LEDs, sound effects, gesture-based firing).
• Finished props — when offered, built and finished here to the same standard as our own personal builds.
• Custom work — bring us a project. If it's something the workshop can do well, we'll see what's possible.

Most of what the workshop sells started as a problem in one of my own builds. I research the source material, model the part, prototype it, build the electronics, write the firmware, and then break it repeatedly until it stops breaking.

One recent example is the linkage connecting the Whistling Birds push arms to the LED housings. It’s a small part, and it’s what makes the module’s universal fit possible.

The alternative is building the mechanism in place, which means the gauntlet’s top enclosure has to come off — and on plenty of gauntlets, it doesn’t. The linkage removes that requirement. The front modules seat into the nozzle holes first, then the gearbox and electronics slide in behind them and connect to the front by feel: three linkages, each one connected with a single finger, in a space that fits about that much.

Getting there took roughly thirty printed versions — hooks, tabs, and several other ways of joining two pieces that have to meet blind, at an angle, with nothing to brace against. A French cleat turned out to be the answer: angle the top of the cleat into the holder, press until it slides home, and it stays put. Five more revisions to the dimensions, angle, and scale before it worked every time. It’s a ship in a bottle, and it only goes one way — to take the module apart, you pull the gearbox back out.

That’s the standard. Not “does the mechanism work,” but “can someone install it one-handed, in a gauntlet whose top doesn’t come off.” And once it’s in — does it work in the position you’ll really be in when you need it. Half in costume, in a hotel room, running late.

My software background shows up in how I get there: define the problem, break it into parts, test the assumptions, find the failure point, and repeat. When a design finally holds up, it goes into the shop as a digital file, a kit, or a finished assembly.

I want you to end up with something you’re proud of. If a part arrives incorrect, or fails because of how I made it, I’ll make it right. Ask questions before you order, during the build, or when something isn’t behaving as expected, and you’ll get an answer from the person who designed or built it.

What I can’t promise is the outcome of a build I’m not doing. This is handcrafted, made-to-order work going into costumes I didn’t make, at scales I didn’t choose, in materials I’ve never seen. Once a physical part has been installed, modified, or finished, it has become part of your build and generally can’t be returned. Digital files also can’t be returned after download. Complete terms are in the shop policies and individual product listings.

Quality at any budget. Same standard whether you’re buying a $50 raw print or a finished kit. Nothing ships that I wouldn’t use in my own costume, and when you hit a problem, I’ll help you find the cause and work toward a practical solution.

Almost everything I know about prop making came from another maker documenting a technique or taking the time to answer a question.

Foxhead Workshop tries to pay that forward through detailed build guides, installation documentation, firmware updates, reference research, and the development work behind each project. The guides hub collects step-by-step walkthroughs — primer technique, beskar metallic finish, electronics installation — written from the bench, with the gotchas left in.

I’d rather show the failed versions than only the finished photo. The thirty linkages are often more useful than the one that finally worked.

Whether this is your first costume or you’re adding electronics to a build you’ve worn for years, the goal is the same: useful information, parts you can rely on, and a shorter path from an idea to a finished result.