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Fabricating Helmet Prototype Display for a Tradeshow

  • Apr 12, 2022
  • 1 min read

Updated: Sep 19, 2024

We were recently approached by Kav Sports to create a 4ft foam hockey helmet for a trade show they are participating in

The customer provided us a smaller 3D printed version of the helmet prototype. They asked us to create a 3D machined helmet that can be broken into pieces then put back together.

We started out by CNC machining the helmet shape pieces on our CNC router, using 2lbs EPS foam, then sanded all pieces thoroughly.

  • Hockey Helmet Foam Prop parts fabricated by WeCutFoam
    Hockey Helmet Foam Prop
  • Hockey Helmet Foam Prop parts fabricated by WeCutFoam
    Hockey Helmet Foam Prop
  • Hockey Helmet Foam Prop parts fabricated by WeCutFoam
    Hockey Helmet Foam Prop
  • Hockey Helmet Foam Prop parts fabricated by WeCutFoam
    Hockey Helmet Foam Prop

We then coated it with first prime coat of epoxy and sanded again

  • Epoxy coated hockey helmet prop with hard coating
    Epoxy Coated Helmet Prop
  • Epoxy coated hockey helmet prop with hard coating
    Epoxy Coated Helmet Prop
  • Epoxy coated hockey helmet prop with hard coating
    Epoxy Coated Helmet Prop
  • Epoxy coated hockey helmet prop with hard coating
    Epoxy Coated Helmet Prop

Then came the DryDex spackle - It's a paste we use to eliminate cracks, making the surface smoother and ready for the next coat. And of course - sanded again...

Drydex spackle over a foam helmet hockey prop
Drydex Spackle over prop

Then came the top epoxy coating

  • Epoxy Coated Helmet Prop fabricated by WeCutFoam
    Epoxy Coated Helmet Prop
  • Epoxy Coated Helmet Prop fabricated by WeCutFoam
    Epoxy Coated Helmet Prop

Then came black painting, sanding, then the finish paint

  • Helmet Sports Prop
  • Helmet Sports Prop
  • hard coated and painted helmet foam prop for Kev Sports
    Helmet Sports Prop
  • hard coated and painted helmet foam prop for Kev Sports
    Helmet Sports Prop
  • hard coated and painted helmet foam prop for Kev Sports
    Helmet Sports Prop
  • hard coated and painted helmet foam prop for Kev Sports
    Helmet Sports Prop
  • hard coated and painted helmet foam prop for Kev Sports
    Helmet Sports Prop
  • hard coated and painted helmet foam prop for Kev Sports
    Helmet Sports Prop

The last phase was to create the stand and the base. We also laser cut our logo and attached it onto the stand

Hard to believe this helmet is actually made of foam... Now working on being able to take the parts apart and assembling it all back again.


  • Hard coated and painted base to hold a helmet prop
    Helmet Base
  • Helmet Base for foam prop holder
    Helmet Base
Epoxy Coated Helmet Prop
Helmet Prop for Kev Sports



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