Clever Workaround Turns Cheap Full-Face Sunglasses Into a Convincing Satisfactory Helmet Visor

Most people have never heard of Satisfactory, a factory-building game where you create massive industrial complexes on an exotic world, or MASSAGE-2(A-B)b to be more specific. Few people are aware of the Pioneers who drive the plot, and they wear helmets with those unique wide, tinted visors sporting a hexagonal overlay. Turning that in-game accessory into something wearable requires some major skills, such as molding unique plastic sheets and endless sanding.

The solution is a bit unusual: huge full-face “sunglasses” sold online as a novelty fashion item, with a giant tinted shield that nearly mimics the shape and curve of the Pioneer helmet visor. Instead of having to sculpt a new faceplate from scratch, Punished Props Academy designed everything around this convenient starting point.

Bambu Lab A1 Mini 3D Printer, Support Multi-Color 3D Printing, Set Up in 20 Mins, High Speed & Precision,…

• High-Speed Precision: Experience unparalleled speed and precision with the Bambu Lab A1 Mini 3D Printer. With an impressive acceleration of 10,000…
• Multi-Color Printing with AMS lite: Unlock your creativity with vibrant and multi-colored 3D prints. The Bambu Lab A1 Mini 3D printers make…
• Full-Auto Calibration: Say goodbye to manual calibration hassles. The A1 Mini 3D printer takes care of all the calibration processes automatically,…

They first applied painter’s tape to the visor of the shades to reduce glare, then used a smartphone app to capture a clear 3D image. That digital model was then loaded into Fusion 360 and used as a foundation for the remainder of the helmet shell. The remainder of the design developed organically from there, meticulously contouring to fit snugly around that visor. Symmetry tools ensured that both sides were identical, whereas cuts for the neck hole and face region were designed and pumped out with accuracy, all while keeping wall thickness consistent such that the final print did not feel heavy but was still solid.

Printing happened using a variety of machines, depending on what needed to be done. Larger elements were printed with ABS to increase robustness, while finer features, such as vents and trim pieces, were cast in resin to achieve sharper edges. Parts were separated into manageable portions to fit on conventional print beds, and then reassembled afterward. A little acetone vapor smoothing helped cover layer lines on the ABS pieces, then some automotive filler primer smoothed everything out even more before painting.

The visor itself required only minor modifications: after removing the cheap plastic arms and nasal bridge, they trimmed the shield to fit snugly inside the helmet hole, while a narrow lip around the edge offered plenty adhesive surface. They affixed a clear vinyl sticker created with a vinyl printer to match the hexagonal grid design of the game. The sticker stretched beautifully and smoothly across the curve without interfering with vision, since it allows you to see clearly even in bright light.

Next came ventilation, which involved covering the apertures on the cheeks and lower face with wire mesh, which they obtained in handy sheets from online providers. Tiny 3D-printed features masked the mesh’s boundaries while maintaining the industrial effect. A small blower fan hidden inside draws fresh air through the mesh and blows it across the inside visor to keep it from fogging up, which is useful for wearing at conventions for hours on end.

LEDs concealed beneath the vent holes cast a subtle glow that appears to highlight the game’s illuminated accents. The cabling connects to a simple battery pack, which keeps the entire contraption self-contained. Stuffing the interior with upholstery foam not only provides a more comfortable fit, but also keeps the electronics away from the back of your head, where they would otherwise be in the way.

These final helmets made a big impression at Dragon Con, and they were teamed with similar denim jumpsuits and a lot of reflective tape to truly make the look stand out. People who tried them on reported better-than-expected visibility, no fogging from the fan, and even how pleasantly comfortable they were after hours of wandering the convention floor.
[Source]