The helmet was without question the most challenging piece of armour on the suit. Not only did it have to resemble the signature Iron Man design, but it had to fold up to fit inside of the briefcase as well. Early in the design process I had examined the helmet, and noticed a series of concentric lines that went around the helmet, almost as if they were separate pieces. So, that's what I did.
After a lot of measuring, trial, error and luck, I developed three separate pieces of the helmet which were big enough to fit my head, yet small enough to fit in the briefcase.
I would later sew them onto a spandex faceless hood, enabling them to maintain the appropriate placement on my head, but still retain their "collapsability".
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