True, we can now use thr 3D print solution to create our own rigs, that's what "motion capture design" did for their helmet.
For the facial mocap tracking I used Movimento but you can get equivalent results in Pftrack, Matchmover or 3DEqualizer, then I simply imported the animated points in 3dsmax and linked my facial controllers to them.
Sure, a WiFi transmitter is a better option but I suck so much at simple electronics already lol
For that short film I worked on shots that didn't made it in the final edit. The most complex one was facial mocap (all the complex preparation explained in the making of) + full body mocap (trackers based), a total of 6 cameras, it was not really enjoyable to manage all that alone with cables running through my body, pushing a simple button to send data via WiFi would have been way more futuristic :)
Here's my facebook, let's keep contact, I'd like to see the WIP of your helmet:
https://www.facebook.com/Nic0lasbrunet