Introduction: INNOVATIVE: 3D Printed Helmet

Authors: Thirathep Sethi, Mitchell Godleski, Ankit Tibrewal

Our 3D helmet design is based on a concept of “Never out of fashion”. Users can print their customized helmets and wear them inside their hoodies. The helmet with have a strap in the bottom for the chin to optimize safety and comfort. A Velcro is set on the top surface of the helmet to attach the hoodie to cover up the 3D printed helmet.

This instructable will guide you through the step-by-step process of designing a 3D Printed Bicycle Helmet using Autodesk's 123D Design.

You can download the software (if you don't already have it) at .

If you are unfamiliar with this program, you can view an overview and watch the tutorial linked below.



This design process is quick and simple so it doesn't require much time. The estimate design time is between 1 - 2 hours.

Step 1: Collect All Materials Needed

  1. Figure out your nearest 3D Printer
  2. Watch all 123D design tutorials if needed
  3. Raw materials (plastic)
  4. Velcro material
  5. Strap (accessible in all sport stores)
  6. Sand Paper
  7. File
  8. Computer with 123D design installed

Step 2: Open Up 123D Design

After collecting all the required raw materials it is now time to start the process of designing your own personalized.

  1. Open up your own 123D Design
  2. Click on start a new project
  3. On the top left of the program hover on the logo and scroll down to save your document
  4. Save your copy to your designated choice as a 123D document
  5. Now you are ready to start the process of designing your helmet

Step 3: Creating the Structure

  1. On the top toolbar hover on the primitives tab and select 'insert a box'
  2. Insert your desired helmet size (depending on your head size) in the bottom of the screen and hit enter
  3. Now sketch a square of your desired size on the current box and extrude it on the construct tab on the opposite side so that the square has removed part of the box

Step 4: Fillet - Structure

It is now time to fillet every side of the box structure to continue the procedure of making it look like a helmet.

  1. Select on the desired size you would like to fillet
  2. Once selected click on the fillet option on the modify tab
  3. A tab will pop-up to enter in the required amount you would like to fillet the side by
  4. Enter 10 on the pop-up so that the side selected is fillet
  5. Repeat steps 1-4 for every side of the box like structure

Step 5: Chamfer

  1. Orbit your design so you're now looking at the back of the helmet
  2. Using the chamfer tool on the modify tab select on the two sides/edges of the helmet
  3. Enter distance for chamfer (recommended size is 15)
  4. Once both sides are completed, create a mid-point for both the sides using the sketch tool
  5. Now chamfer the two bottom-sides (recommended size is 20)

Step 6: Designing the Bottom Structure

  1. Orbit your design so you're now looking at the bottom of the design
  2. Now select the shell feature on the modify tab
  3. This will now create a hole for the top of the helmet (select the thickness as per your preference)
  4. You can also change the color and material of the design by selecting the design and select materials on the bottom toolbar (ensure that material is plastic)

Step 7: Vent Holes and Velcro

It is now time to finish the final touches of the product by adding the Velcro cut as well as the vent holes.

  1. To add the vent holes on the top of the helmet all you had to do is use the sketch tool and create a rectangle on the top of the helmet
  2. Now copy that rectangle and paste it 5 times parallel to the first rectangle
  3. Now extrude all rectangles (-10) to make the vent holes
  4. For the velcro, sketch a rectangle on the top of the helmet and pull it (+2)
  5. Your velcro and vent holes are now complete

Step 8: Congratulations - Final Touches



  1. Save your 123D Design as an STL file. Depending on your 3D printer, slice your design using the printers software and send it to print.
  2. Once printed, you have the option of adding the velcro and strap on to your 3D printed helmet

Once again, congratulations on printing your new 3D printed helmet