Yeah, I?d lose the PERS and ditch the one piece rubber suit. This has been discussed for years.
Give him a new cowl head with no seams. Design it like BvS Affleck and have the three eye plate panels (netrual, looking to the left, looking to he right) that feed up into the figure?s head. Give him 4 new faces that are actually different from one another. An angry face is a must.
The suit should be a cross between their Spider-Man/Stormtroopers/TDK Batman. Under suit made out of fabric with 6 pieces of sculpted plastic vinyl, silicone chest/torso armor, leggings, forearm and knee pads sewn and glued over top of it. No rubber, all the articulation one could need. Simple as that.
Make sure the elbows and knees are on ratchets for extra durability and make a nice thin cape with some weight to it with no gimmicks. Boom. Done. $280