Not exactly the latest, snow sports production work from 2012. Ski and snowboard crossover helmet. Polycarbonate thermoformed in-molded shell with BOA adjustment system.
This was the evolution of the previous model helmet that followed a clay-to-digital workflow. Clay sculpting of the prototype helmet shapes had been an integral part of sports helmet development. Although surfacing tools had been in place for a decade at least, sports companies did not trust them 100% yet, especially for helmets where very subtle variations are fretted over, akin to phrenology. Confidence in the fidelity of the surfaces throughout the previous hybrid workflow, digital-to-clay-to-scan-back-to-digital, allowed us to set this following model up differently.
Lightweight foam models were cut and others 3D printed to be fit-tested and matched with goggles during the confirmation stages.
This helmet model development was digitally based from the start, specifically because of the tools and workflow made possible by Rhino.
The overall volume was determined and the sketch work began. This method was to sketch on faded printouts and allow for re-importation, 1:1 scaling of the features.
One developed personal approach is the draw construction lines, a project-specific grid on the 3D, and use that as an assist for accurate 3D vent or feature sketching in non-planar views. The orthographic top and side views do not communicate an accurate impression due to curvature and perspective.
Once a vent design was selected, roughed into the CAD shape and then the 3D renders painted over to maintain a sketch mindset without sweating the finer surface details during review.
On to a more detailed 3D and renders, keeping the clay look initially.
And then the deep dive into the production surfacing, as minimal as possible given the details and transitions, molding considerations, venting and hardware, and fit system integration. Finally, after the first tooling test confirmation, the creation of different sizes/headforms maintaining foam thicknesses and fixed hardware constraints.