TOS - Mirror McCoy
I made both the normal and a mirror universe version of McCoy. The shirt was purchased, but I modified the striping (originally Spock's). The knife and tricorder were 3D printed with an LCD photo keychain added to the tricorder for a viewscreen. I modified the bottom of the pants, and for the mirror version, added the belt fabric, and created some medals using 3D printing.
TNG - Borg
The Borg was my first costume. It remains one of my heaviest, even with 15 lbs already removed (thumbnail pic by Wandering Dana). It's made of every bit of junk I could find glued down to football padding, a bought mask and an artificial arm made from aluminum tubing. I made a puppeteer mechanism inside to control some sensor like gadgets on the outside.
TNG - Commander Riker
This was a purchased costume. I made extra communicator pins and pips to supplement my collection and change to future versions. I originally made a communicator with an MP3 player too, but sadly it was lost. I also made the Geordi visor from aluminum sheet and a brass screen.
TNG - Risa Riker
This was for some pool fun at Yeticon. I 3D printed a Horga'hn, a communicator and The Game headset to go with my swimwear/bathrobe.
All images copyright Rob Emery