GoPro Custom Clip for Downhill Skateboarding Helmet

Challenge

I wanted to mount a GoPro on my New Olders Blackbird helmet, but its unique chin geometry made it impossible to use standard flat or curved clips. None of the existing mounts fit properly, so I set out to design a custom, made-to-measure clip that could adapt to the helmet and withstand the demands of downhill skateboarding.

Process

The project started with a set of requirements: replicate the helmet’s geometry, test printing materials (PLA, TPU, PETG), ensure the clip’s tolerance and weight, validate the GoPro’s fit, and optimize the printing profile to minimize supports and material waste. Adding my personal logo was considered a bonus, not a must.

Using Shapr3D, I modeled the helmet’s chin geometry to design a precise-fitting clip. I went through several PLA prototypes, testing both the helmet fit and the GoPro attachment. Once the design was working, I refined the form and printing orientation for better quality and efficiency.