The Grapple Pilot Helmet project began several years ago. We created the 3D model, printed a miniature version, and painted it to see the design as a physical object.
At the time, there was not enough audience interest to justify taking the helmet into full development, so the project stopped there.
Over the past year, interest in the Titanfall universe grew again. We returned to the old project and decided to take the Grapple Pilot Helmet from a digital model to a helmet ready for regular production.
Printing the Full Helmet in High Detail
For this project, all parts of the Grapple Pilot Helmet master were produced using photopolymer resin 3D printing. Once the full set of components was printed, we moved on to assembly and post-processing.
This printing method allowed us to reproduce the complex geometry and fine surface details of the helmet clearly. But even a detailed print still needs to be checked as part of the complete assembly.
A part can look correct by itself and still fail to align properly when the entire helmet is assembled.
When the Parts Came Together
After the main helmet components were assembled, we began fitting the remaining parts and checking their mounting areas.
Several parts did not align correctly with the surrounding geometry. Instead of compensating for these problems by hand, the affected components were sent back for remodeling and then reprinted.
Printing, fitting, remodeling, and reprinting were necessary to make the separate parts work together as one physical object.
At the same stage, we also reviewed which components should remain removable and which should become fixed parts of the finished helmet.
The Mesh Detail
One detail required a separate solution: the mesh on the crown of the helmet.
We tested different mesh options and decided to use real mesh on the master during mold production. The finished helmets, however, would not use a separate piece of mesh in this area. Its texture would be reproduced directly in the casting.
The mesh was later remodeled and reprinted before the final helmet version was approved.
From Printed Parts to a Master Model
Once the geometry and fit were approved, the printed parts still had to be prepared for mold making.
The surfaces were sanded and leveled by hand. Filler was applied where necessary, joints and transitions were refined, and the prepared parts were primed.
This removes printing artifacts that should not appear on the final cast helmet. Any surface defect or inaccurate joint left on the master can later be transferred into the mold and repeated on every casting.
The components were repeatedly assembled and checked during finishing. Once the remaining parts had been installed and post-processing was complete, the master was ready for mold making.
Making the Main Helmet Mold
Casting the main shell required both a flexible silicone mold and a rigid support shell to hold the silicone in the correct shape.
First, the mold maker secured the master model to a base and covered it with film. A layer of plasticine was then applied over the helmet. The thickness of this temporary layer established the space that would later be occupied by silicone.
A thin layer of blue silicone was applied over the plasticine. At this stage, it acted as a separator and prevented the rigid shell material from bonding to the plasticine.
The rigid support shell was then built up in layers around the helmet.
Alignment holes were made through the base and the cured support shell. These allowed the shell to be returned to the same position around the master model later in the process.
Once cured, the support shell was removed and the plasticine and film were stripped away. A pour opening was made in the shell before it was returned to the base, aligned through the prepared holes, and sealed in place.
Silicone was then poured into the space between the master model and the rigid support shell. Once it had cured, the main helmet mold was complete.
Casting and Demolding
The process begins with the silicone mold. We apply talc to its inner surface and blow away the excess.
We place the mold into the “drum” — a centrifuge that rotates in three planes.
Next, we mix a casting plastic developed specifically for this process and pour it into the mold. As the machine rotates, the plastic is distributed evenly across the mold walls, forming the main helmet shell.
After the plastic has been distributed, the mold is left for three hours until the material has fully cured.
Once the plastic has cured, we remove the support shell and begin pulling the silicone mold away from the helmet. Demolding one helmet takes approximately 15 minutes and requires steady physical effort.
Finishing the Casting
The helmet is now out of the mold, but it is not yet ready for painting.
At this stage, we cut away all unnecessary plastic, including the remaining casting sprues, and open the area for the visor. We also drill the holes that will later be used for attachments and other installed components.
Finally, we sand the surface to level it and create better adhesion for the primer and paint.
The separately cast components are also finished by hand: excess material is removed, the edges are cleaned, and the surfaces are prepared for painting and assembly.
Choosing the Final Colors
After the first casting was prepared, we moved into paint testing.
We made color samples and compared different shades before approving the final palette. Once the colors were selected, the first helmet entered the paint stage.
We use automotive-grade paints and professional automotive painting techniques for our helmets. The finish is built in layers, with masking used to separate color zones and graphics before the final protective finish is applied.
The painted helmet was then reviewed as a whole to check how the colors, graphics, surface finish, and separate details worked together.
Developing the Visor
For the Grapple Pilot Helmet, we use colored acrylic with the characteristic honeycomb engraving.
First, we cut the required shape from acrylic and apply the engraving. The acrylic is then heated in an oven until it becomes flexible.
While the material is still flexible, we place it inside the helmet and allow it to cool and hold the required shape. Only after that is the visor securely fixed inside the shell.
The visor is available with standard blue lighting or RGB lighting.
Lighting, Electronics, and Interior
For the Grapple Pilot Helmet, we used the same basic lighting and interior solutions already used in our other Titanfall helmets. The electronics are developed and assembled by our team, while the inside of the helmet combines foam padding with a specially sewn fabric liner.
Final Assembly
Once the paint, visor, electronics, and interior were ready, all components were assembled.
The finished helmet includes the colored acrylic visor with honeycomb engraving, lighting, three Velcro panels, a functional flashlight, an illuminated camera, four straps, a real cable, and the detailed graphics visible on the in-game design.
Several years ago, the Grapple Pilot project stopped at a painted miniature. Today, it is a finished helmet ready for production.
See the finished helmet, available options, and full specifications on the Grapple Pilot Helmet product page →