Step 5/5. Duplication

This is the fun part. You have your Silicone mold which scanned the surface of your object, to prevent the silicone from withering you made a fiberglass cast for the flexible silicone to cling to, giving it structure. Into this cavity you pour your choice of plastic resin. Depending on your choice of resin you could determine cure time, flexibility, impact resistance, brittleness, etc. etc. Be sure to read all handling and curing instructions and ensure that you are using it correctly and that your resin is compatible with your silicone mold. . By pouring more or less you determine thickness. We rotated the helmet with some finesse to ensure all corners of the mould were covered with our plastic resin. When it was apparent that it has become viscous beyond moving we set it down and let it cure. Once the prescribed curing time had passed we unbolted the two piece cast, flipped the Copy out of the silicone mold and voila you have a copy of your prototype!

Get a more in depth introduction to our helmet and its handmade construction when funding our Kickstarter. The “Retrospective Making-Of” has a special segment dedicated Rider Real’s suit and helmet design and construction, with interviews of the designers and molders.

Also I have Helmet Help where will provide advice via skype to anyone requiring assistance!