This is extremely interesting. I must admit, I am not very familiar at all with the process of making figures like this. I'm an artist, I work w/ polymer, and I've cast metal before, but I'm very curious about the process & materials that you use! I think it seems very foreign to me, because I'm used to working with material that's "forgiving" and "works with you." But when you make something like this, it seems as if you would be fighting against the materials you have to use the whole time!
What I mean is, if I were to attempt to make something like this, I would want to make all the articulated joints and then cover the whole figure with some sort of thin rubber layer, I guess kind of like the Barbie dolls you see. (I guess they're still made like that!) But from what I unerstand, you can't use material like that, since it won't hold up after years & years, & will disintegrate. Therefore you have to use this unforgiving material...
Anyway, hope all that made sense. I enjoyed looking at Leia. Her face sculpt looks very, very good. And I love the fact you sculpted the little knee joints - why don't other people do that? It just makes sense.
I'm impressed, and very curious now about the whole process of making something like this...