PROPS
As shown in the video and photos below, the helmet had to be milled both inside and outside. That was accomplished by constructing the helmet out of two, interlocking halves that perfectly fit together. A draft version of the helmet was first milled in extruded polystyrene (XPS) foam to test the process (grey helmet in photos below.) Then a final version was milled in polyurethane (cream-colored helmet below), before a final paint job.
