The above part is the shell of a Surgical Helmet. The helmet offers protection from fluids during operations, and has a ventilating fan enclosed in it and a plenum running over the top of the head to distribute cooling to the face. It is made in the twin-sheet thermoforming process. It features a very complex curvilinear parting line. It is made from a Polypropylene co-polymer, and the starting gages of the sheets are .055" and .065". The part is extremely light, weighing under three ounces. The insert picture highlights the face shield mounting feature. This is essentially two material thicknesses molded on both sides for strength and is held to close tolerances. The biggest challenge in producing this part is not the molding but rather trimming out such thin material.