For Toronto Fan Expo 2018, we were tasked with creating three additional Level 3 PUBG helmets for the Xbox Canada booth. To speed up production, we used the original helmet from the first build as a base, making minor repairs with Bondo, Free Form Air, and molding putty before applying spray filler and a gloss clear coat for smooth molding.
The molding process began with the faceplate, using Smooth-On Rebound 25 silicone for flexibility and a rigid foam mother shell for structural support. The helmet base followed a plaster bandage molding process. Using a slush cast method, we created multiple semi-rigid resin copies, trimming and refining each with rotary tools, files, and sandpaper.
For a battle-worn look, we applied a matte black base coat, followed by aluminum dry brushing and weathering washes. Pivot-mounted faceplates, custom plexiglass visors, and memory foam inserts were added for function and comfort, with finishing details including a company logo.
Just like that, four new Level 3 PUBG helmets were ready for action!
