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| When the modeling was completed, we output a SLA (stereolithography) model of the helmet, took it to Lucasfilm for their approval and then forwarded it to our factory in China. We also took the decision to make the black “rubber” trim around the top of the helmet in rubber instead of simply painting it black. The factory “removed” the strip from the top of the helmet so it could be added back later after molding. We also supplied the design for the rear “mohawk” red reflector, with instructions that they make it light.The factory worked quickly to make the first engineering prototype. The FEP is useful for a number of important reasons - it checks the manufacturing processes and shows where, if any, potential difficulties might lay. It also provides the factory their first opportunity to quote an accurate cost, since what was previously a theoretical helmet is now a real, actual product. The test helmet was shipped back to the US for comments and approvals. |
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