How It's Made

From Digital Spark to Physical Masterpiece

At Redbone Forge, we don’t just hit "print." Every helmet is a journey through precision engineering and custom design. Here is how your gear goes from a concept to your front door.

STEP 1. Digital Theming & Scaling

It starts with the blueprint. We take a base helmet design and theme it to your specific team or character, choosing colors and layouts that respect the original source. Once the design is set, we scale the entire file digitally to match your measurements. No "one size fits all" here—your helmet is scaled for you.

STEP 2. Material Engineering & The Big Print

We don't use generic hobbyist plastics. We carefully select every roll of filament based on two non-negotiable standards: vibrant color depth and industrial strength. This meticulous selection ensures your build is tough enough to last for years of use, with colors infused all the way through the material so they never chip, fade, or peel. For complex designs, a single piece can take several days to print.

STEP 3. Post-Processing

Once the print is complete, we manually remove all structural supports and clean the surface. We then use a specialized torching technique to seal the "flavor" (and the finish). This heat-treatment process smooths out micro-textures and gives the material its final, durable sheen.

STEP 4. Industrial Magnetic Assembly

The "snap" you hear when you put on a Redbone Forge piece is science at work. We use ultra-strong N50 to N52 rated magnets. > The Science: The "N" rating measures the maximum energy product of a magnet. While most hobbyists use N35, we use N50-N52 to ensure that once your mask snaps into place, it stays there until you decide to take it off.

STEP 5. Final Fit & Finish

Before any item leaves the forge, we perform a total "Fit and Finish" audit. We ensure the logos are molded seamlessly into the shape of the helmet—not just stuck on. Once it meets our standard, it gets our official Redbone sticker on the interior.

STEP 6. Armored Shipping

We know you're excited to get your gear, so we don't take chances.

  • Insured Shipping: Every order is fully insured.
  • Pro Packaging: Shipped in appropriately sized, heavy-duty boxes with premium packing material.
  • Perfect Fit: We include custom helmet padding with most orders so you can fine-tune the comfort the moment it arrives.