These are of course very good suggestions. For me, I usually just build one or two helmets to get a feeling for the setup and to confirm that everything just works as intended. After that I sell the files, I hardly ever sell any of my own personal builds. Projects always starts off with me wanting to have an item of whatever and then I start modelling it. What I'm trying to say is that it's primarily for my own colllection and secondarily I sell the files to whoever else want a build. Therefore making a mold and casting is neat but a bit too much work for one helmet. Also, I don't really have the setup for it sadly. I have a bunch of printers though....If you have been doing it that way for a while and happy with your own process, I am just offering a suggestion.
I hate heating PetG and vacuforming THEN having to dye it in boiling water. Much easier to just weigh some resin, add a few drops of pigment, degas, pour and done by tomorrow.
If done simultaneously, it isnt a time crunch.
That said, I would love to do resin lenses for this build, I've haven't really done ANY casting since early 2000's so It's a process I'd need to relearn most likely. There is sadly no reseller of Smooth-On products here in Sweden so I'd need to find an equivalent of Epoxacast 690 or such that is available here first as well.
We'll see, Maybe I'll try it, I'll probably will be returning with a bunch of questions if so