I am a graphic artist by trade but part of my job history is Computer aided design. I carefully studied the voicebox, and made forensic photo measurements, and came up with this 3D model...

I sent that model to the company that does my Rapid prototyping and got back a beautiful pattern....
Here is the master pattern for the first season Voicebox

you can compare it to the original...

While I was at it, I made a version for the second seaon style as well...


This has been a very slow and tedious process but i think in the end, it will be worth the efforts...