The Paintball Mask design features a dual-material structure combining the durability of polycarbonate for the rigid upper section and the comfort of TPE rubber for the flexible lower section. The goal was to create a lightweight, impact-resistant mask that ensures high protection and comfort.
Concept & Ergonomic Design
The mask was designed to ensure breathability, facial comfort, and structural strength.
Detailed 3D Modeling in SolidWorks
A fully parametric 3D model was developed with precise dimensions and controlled wall thickness.
DFM Optimization
The model was refined for injection molding production. Wall thickness was standardized to prevent sink marks.
Design for Manufacturing
Draft angles were added for smooth mold release. Sharp edges were minimized to improve safety and tooling life. Undercuts were evaluated.
Production-Ready 3D Model
Final deliverables included manufacturing drawings, and export files. The model is ready for mold fabrication and mass production.
Safety & Standards Audit
Reviewed the original model against ASTM F963 (US) and EN 71 (EU) toy safety standards
Structural & Ergonomics Analysis
Identified weak points and discomfort areas for targetted reinforcement & reshaping
Design for Manufacturing (DFM)
Designed for injection molding, considering draft angles, wall thickness & material flow
Final Integration & Documentation
Delivered 3D assemblies with a report of all safety and manufacturing improvements
Challenge
The Solution
The Result
Ensuring proper airflow without weakening the structure
Optimized perforation pattern with reinforced curved geometry
Improved breathability while maintaining strength
Achieving a comfortable and secure facial fit
Ergonomic contour design based on facial profile geometry
Better comfort and stable positioning during use
Preventing material deformation during production
Uniform wall thickness with added draft angles
Smooth molding process and consistent part quality
Reducing overall weight while keeping durability
Lightweight polymer design with structural rib support
Strong yet lightweight mask suitable for extended wear
Safety standard compliant design
Reliable structural performance
Durable impact resistant build
Perfect for active use, training environments, and situations where protection, comfort, and long term durability matter most.
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