Fire Helmet Memorial Urn - Custom-Fit Base Plate from a 3D Scan

Client: Private customer | Scope: 3D scanning, CAD design & custom printed part

The Story

Some projects mean more than others. This client served as a volunteer fire chief, and his helmet has been with him through all of it. He wanted it to become his urn when he passes, so the helmet he wore on the job could stay with his family as a memorial.

The challenge was turning a helmet into a closed, solid vessel without changing how it looks from the outside. Whatever closed off the bottom had to fit the helmet's opening exactly, sit flush, and look like it belonged there.

Scanning the Helmet

A fire helmet isn't a simple shape. The underside has a curved brim, an inner ring, mounting holes and hardware, and none of it is perfectly symmetrical. Measuring it by hand would have been guesswork, so I 3D scanned it instead.

I placed scanning targets around the underside of the brim so the scanner could track the surface accurately, then captured the full opening and brim.

The result was an accurate digital copy of the helmet's underside, including the inner ring, the brim curve and the existing mounting holes.

Designing the Base Plate

Using the scan as a reference, I modeled a base plate in CAD that follows the exact outline of the brim. It lines up with the helmet's existing holes, so it mounts with hardware instead of glue and nothing on the helmet itself has to be modified.

Test Fitting

Before printing the final, I printed the plate in black to check the fit. It mounted flush to the bottom of the helmet and followed the brim's shape all the way around, with the holes lining up where they needed to.

The Result

With the fit confirmed, the final plate was printed in white PETG to match the helmet. PETG is tough and holds up well over time, which matters for a piece meant to last for generations. From the outside, the helmet looks exactly as it always has.

It was an honor to help with a project like this. His helmet will stay with his family, just the way he wanted.

Have a keepsake, heirloom or memorial piece that needs a custom part made to fit it exactly? Reach out and let's talk about what's possible.