While I have always been opposed to the System incarnation of Bionicle, I would love to see the CMF series done in this style. What do you think? What characters should LEGO present if we assume they can only choose 12? I would bet on Tahu, Kopaka, Lewa, Gali, Onua, Pohatu, Takanuva, Teridax, Mata Nui and… I’m not sure about the other three.
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We need villains.
Considering how mass produced the villains of the first half of Bionicle are (yes, Rahkshi weren’t mass produced in 2003, but they were mass produceable), we need more rahi, bohrok & rahkshi.
Plus we can have multiple villians in a set! Just look at the hero to villain distribution in lego sets. As long as the frequency of the villians is proportionate to their rarity (bohroks are common & rahkshi are rare).
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Have you considered using a 3d software to create the masks such as Blender? I mean you could use different models together from different sources, combine them and smooth it out. And once that is done you could get this 3D printed and then try to sand the models to make the 3D prints smoothed-out and, yeah it may look too big but you could use them as prototypes for the project.