GINO
Sr Member
As far as how the material selection affects overall cost of the item, it's hard to predict.
Contrary to popular belief, just because a product is made in plastic doesn't guarantee it's going to be less expensive to make over the course of development/production.
There are a lot of other things to consider such as complexity of the product, and time training the factory to produce parts that are consistent and meet quality standards, familiarity with the medium, assembly issues, etc.....
The PCR helmets were injection molded. Injection molding produces practically identical parts every time.
You invest a $ignificant amount in the tooling up front, but then production is fairly smooth there after.
You cannot produce injection molds for a sculpted form like a trooper helmet without sacrificing a significant amount of accuracy.
In doing so would lose every nuance captured from having something directly cast off an original.
Vac forming is a different animal entirely from injection molding.
Consistency of the parts is not guaranteed, and then the pieces have to be trimmed and assembled to spec.
Many in the hobby have done this without issue on a small scale.
But when you are talking 1000+ pieces over a short time (production time in a factory is scheduled and happens pretty quickly once the rubber hits the road), it's significantly more difficult.
We'll just have to wait and see.
In the end, just take comfort in knowing that whichever way we go will be in the best interests of our greatest number of customers.
.
Contrary to popular belief, just because a product is made in plastic doesn't guarantee it's going to be less expensive to make over the course of development/production.
There are a lot of other things to consider such as complexity of the product, and time training the factory to produce parts that are consistent and meet quality standards, familiarity with the medium, assembly issues, etc.....
The PCR helmets were injection molded. Injection molding produces practically identical parts every time.
You invest a $ignificant amount in the tooling up front, but then production is fairly smooth there after.
You cannot produce injection molds for a sculpted form like a trooper helmet without sacrificing a significant amount of accuracy.
In doing so would lose every nuance captured from having something directly cast off an original.
Vac forming is a different animal entirely from injection molding.
Consistency of the parts is not guaranteed, and then the pieces have to be trimmed and assembled to spec.
Many in the hobby have done this without issue on a small scale.
But when you are talking 1000+ pieces over a short time (production time in a factory is scheduled and happens pretty quickly once the rubber hits the road), it's significantly more difficult.
We'll just have to wait and see.
In the end, just take comfort in knowing that whichever way we go will be in the best interests of our greatest number of customers.
.