Ok. Last one for now.
Here you can see some actual printing and that same piece at the tip of one of the finished ears. (Minus curl.. will be mostly fluff)
The ears were a bit more complicated due to weight shifting, but I found a really nice workflow. some of the gaps will be filled in with foam.
Structurally, I could take any one of these final parts and throw them at concrete and they would be fine.
ABS has a rigid form but a little give. I change this by making the walls thicker or thinner.

Thanks for watching. More will be posted when there is more to show.