Helmet Cap

My dad has to avoid the sun on his head when being outside. He likes riding his bike and wears a helmet when riding.

He used to wear a cap under his helmet, but with his new helmet there's no space for a cap inside.

So my mom started sewing him a helmet cap for the outside of his helmet. After several prototypes failing, mostly because the wind would blow the cap up, I decided to give it a try with my 3D printer.

This prototype actually works great for my dad, so I'm sharing this so other people can make it, if they have a need for it.

What I used for making the helmet cap:

1. PLA
2. foam
3. Elastic band
4. Optional: A pre-made helmet rain cover or some fabric to make your own.

I used Thinkercad to make the design for the cap.

I attached the .STL file to this step. That should make it easy for you to just print the cap. If your helmet has a different size or shape, my design might not work for you.

So I also shared the design on Thinkercad, here's the link to that: https://www.tinkercad.com/things/j1KHoWpMf0s-helmet-cap?sharecode=XPiAEj91hAvASQo4LFoJztCdci6R9PAQluS_BmVI2ps

Feel free to change it any way want.

Use your 3D-printer to print the cap. It took me about 2 hours to complete, with an older 3D-printer.

I used PLA for the print.

After the print was completed, I added an elastic band through the slots in the cap.

Next i added some foam to the back side of the cap. This helps to prevent the cap from sliding off.

The helmet I used had screws on the sides for a visor, that wasn't used. I attached the elastic band to those screws.

If your helmet doesn't have those screws you can make a band that goes completely around the helmet.

Make sure the elastic is tightly around the helmet.

That's it: you've finished the cap.

Since my dad needs the holes on top of the helmet blocked off, I added a rain cap to the helmet.

The rain cap has an elastic inside, which also helps keep the cap in place.

You can also make this yourself with a piece of fabric and an elastic band.

My dad has been testing it out and he's ridden over a 100 km's and the cap hasn't moved at all. So i'd say that the cap is a success.