I am finally able to offer something definitive to this Definitive Helmet Research Thread:
DREDD HELMETS FROM THE MOVIE - OVERVIEW
Here is a collection of knowledge about all of the helmets from Dredd 2012 based on fan observations and on discussions from the crew. Wherever possible, quotes have been dated and attributed. Some crew members have weighed in publicly, some privately. Obviously, input from the people who actually worked on the movie carries a lot of weight, but remember that these folks worked on the movie several years ago, and memories are not perfect.
Note: For the purposes of this document, we will not be discussing the prototype helmets that were created and rejected prior to the start of production, but you can see a photos of them here:
http://www.propstore.com/img/products/2310/Proto003a.jpg
and here:
http://www.empireonline.com/images/image_index/height200/67811.jpg
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There are currently THREE known sizes of helmet from the movie. Two male and one female. We'll go over the female helmet first, since there is much less info to cover about that one.
The female helmet was worn by Judge Kaplan and by Anderson (briefly). This helmet had only one master mold. It was a very small helmet. To quote a crewmember: "Olivia's got a tiny head".
There were some female helmets sold in the Propstore auction, but to date, no one has offered any screen-cast replicas for sale.
The male helmet originally had one master mold. This was the one used for all of the male judges (including Dredd), as well as the Hall Of Justice security guards. Several helmets of this size were sold in the Propstore auction. One of them was bought by Steve Noden who has cast replicas which many fans have bought. For that reason, this helmet is sometimes referred to as the "Noden" helmet. (It should be noted that the Steve Noden helmet did not come with a helmet badge/crest and so the helmet badge on it is fan-sculpted).
At some point during filming, a second male helmet mold was made. This was done by simply cutting strips out of the standard male helmet, and gluing the thing back together to create a slightly smaller helmet. This was done because fan reaction to the size of Dredd's helmet in the first photos released from the movie had been so negative. A mold from this cut-down helmet was made, and at least three helmets were cast. (Two were sold as unfinished helmets in the Propstore auction, and at least one finished helmet was made).
The two unfinished versions of this smaller helmet were purchased by Joe Browning and he has made a cast available through his company JBReplicas. For that reason, this helmet is sometimes referred to as the JBR helmet.
There was some debate as to the very existence of this smaller male helmet for a while, but the above information has now been verified. The only thing that has not been verified is whether or not Karl Urban ever wears it in the film. What IS certain, is that Karl wears the larger helmet (the Noden helmet) in most or all of the movie. But it is possible that the smaller helmet (the JBR) appears in a few shots - the shootout with Lex, for example. And, while not yet verified, many people are convinced that Karl is wearing the smaller helmet in the series of in-studio publicity photos. Example here:
Tutte le dimensioni |irQwb | Flickr ? Condivisione di foto!
The Noden helmet is currently still available via Facebook. The JBR is being offered on both Facebook and TheRPF.com (the JBR helmet was sold by Propstore without a helmet badge, so that helmet has a fan-made badge as well).
Here are some relevant crew member quotes regarding the information above:
First Daniel Carey-George (of Planet Replicas) quoted a source from the production back in 2012 who worked directly on the costume:
"and there are two sizes in the film...of dredds
one in the first half and a slightly cut down one of ours after all the helmet bashing"
Because this quote says "in the film" it leads us to believe that the cut-down (JBR) helmet may have seen a bit of screen time.
The same source went on to be more specific about how much was cut out of the helmet:
"there is not much in it at all. 2 cm at the side and 2 cmm out of the back.....done badly as well but i spoze they were under some pressure"....
Michael Van Kesteren (who did weapons on the movie, including the big gatling guns) weighed in on Facebook on May 31st of 2012:
"Okay guys, I've been asking some of my mates who worked on the movie. We took a full sized one (the larger one) and cut it up, reshaped it (fill, sand, repeat) to create the smaller sized one for Karl. At the last minute it was then reverted back to the original. According to the props master."
When asked whether or not the JBR ever appeared onscreen, Michael then responded:
"From what I understand (they never let me near set), they used the big one (much to Karl's chagrin, by the way) for the movie. But it did then give us an intermediate scale."
If further information comes forward, I will add it to this document.
Helmet paint etc.:
Per Rob Allsopp and Chris Jack (Dredd propmakers):
(paraphrased to condense)
The helmet is gloss black, with gloss red trim. After painting, there was a lot of breakdown/weathering work.
The exact color of red was a custom mix. The helmet badge was cold cast brass (with brass powder throughout the resin). It was then finished with a combination of buffing (to shine the metal powder), black paint, graphite polish, and french enamel varnish.
Note: Though the red paint was a custom mix, very close matches to the color are out there. (see the paint resource guide document in the Judge Dredd DragonCon Facebook group "files" section):
https://www.facebook.com/groups/DreddCostumeGroup.DragonCon2013/doc/483929421675305/