Overall, approximately 40 3D printed parts were used to create the final helmet. The majority of the parts were created on an SLA system utilising Accura 25 (a general purpose material), due to its ability to create accurate models with good impact strength, good heat deflection and excellent surface finishes. SLA (Accura ClearVue) was used to produce the clear visor. The smallest and functional components were a mix between SLA, SLS (Nylon 12) and DLS (RPU70). Materials were chosen to meet the functionality needs of the gears, fixtures, connectors, and smaller flexible parts.
Each of the parts were sanded, primed and painted using a 2-stage automotive grade, color matched paint. The vector logos and markings were converted into PMS color matched decals and applied before the final clear coat, which protects them from being scuffed or scratched. The SLA clear visor was hand sanded to a near mirror finish, then protected with a UV resistant automotive clear coat (color tints may also be applied to clear parts when needed). Actual hardware was sourced for assembly and gaskets, while the foam liner was modified from an existing helmet.