This week we are featuring a very special Project of the Week! In September, we received a phone call from a local mom who wanted to do something special for her 7 1/2-month old son. Her son was getting a cranial orthotic helmet, and she had been researching ways to make it something extra special. She came across a company on the west coast that customizes orthotic helmets with vinyl wraps. Since that company was so far away, she contacted us, hoping that we could offer a similar service locally. Without hesitation, Murray (our owner) and Rich (our Director of Wrap Installation) offered to not only wrap the helmet but to also donate the materials and time to install it.  

The first step in this exciting process was to meet the little guy (oh my cuteness!). Then we needed to start on a design and create a template for the helmet. The mom sent us a photo of an aviator look that she liked. She also brought her son to our shop with his helmet, and Rich used the helmet to fabricate a custom template for the design. Once we had the template made, we were able to take the photo she sent to us and design an aviator helmet just for him. (I know I should hold off on this reveal until the end, but I just can't wait!)

I don't think you can find a cuter pilot than this!

Zane, one of our talented graphic designers, created the one-of-a-kind aviator helmet. We didn't want it to have too rigid of a look, and Zane did a great job of adding dimension to the helmet with the curves and shadows in the seams and the straps. Zane added aviator goggles and a compass to the helmet design, and it was complete. One we got the approval from the little pilot's parents, we were ready to print. 

The custom aviator design for a cranial orthotic helmet.
Zane added little details and features to make it look like the real deal!

We digitally printed the custom design on Avery MPI 1005 Easy Apply RS vinyl with an Avery 1060 overlaminate. The Avery Easy Apply RS vinyl is repositionable and slideable, which helped with installing it on the contours of the helmet. To add a special touch, Rich used a textured brown leather vinyl on the back of the helmet, which really added to the authentic look.

A side view of the helmet, showing the compass and the brown leather vinyl.

Rich came in on a Saturday morning to complete the helmet - just in time to get this little pilot and his parents off to a Halloween party! We were lucky enough to see a photo of the adorable family in their Halloween outfits, and they made a great looking trio. 

We can't pass up the chance to let you know a little more about why this little pilot is wearing this helmet. He has a condition called Plagiocephaly, which causes an infant's head to have a flat spot and be misshapen (or asymmetrical). The helmet consists of a foam lining covered by a hard outer shell. The helmet provides gentle pressure on specific areas of the head that assist with shaping the infant's skull. Adjustments frequently are made on the helmet as the infant continues to grow. An infant is required to wear the cranial orthotic 23 hours a day, and it is only taken off during baths.

The doctor said our little pilot would need to wear his helmet for six months; however, we are happy to report that he is doing great and may not need to be in it for that long! His mom also reports that, even though he has to be in it for most hours of the day, the helmet does a wonderful job of protecting him from the bumps and bruises he could be getting as he crawls around and pulls up. Sounds like a WIN-WIN!

We are so happy that we were able to be a part of this custom wrap! Our team loves the opportunity to try new projects. (Well, as long as the project falls within our company's guiding principles.) Are you looking for something new and different? Let us know how we can be of service!