To get the rounding I have in my armor, make sure to ‘make up’ by rounding off the polygonal shapes where needed, and add sharp corners where the Varia suit requires them.
You should only cut along the red shell lines. To get the least additional seams possible, merge darts in the patterns together and heatshape where possible. You can emphasize these lines in 3D by lightly dremeling the corners before glueing it together. The patterns seams are aligned with the dark texture lines in the Varia suit reference itself, so minimal seams are achieved.
