Blue Gauntlet Fencing Helmet Ear Grommet

Our Larval Engineer practiced fencing for several years, learning the fundamental truth that you should always bring a gun to a knife fight:

Fencing - taking a hit
Fencing – taking a hit

It’s time to pass the gear along to someone who can use it, but we discovered one of the ear grommets inside the helmet had broken:

Blue Gauntlet M003-BG Helmet - broken ear grommet
Blue Gauntlet M003-BG Helmet – broken ear grommet

The cylinder in the middle should be attached to the washer on the left, which goes inside the helmet padding. It’s a tight push fit inside the washer on the right, which goes on the outside of the padding. Ridges along the cylinder hold it in place.

Being an injection-molded polyethylene part, no earthly adhesive or solvent will bother it, soooo… the solid model pretty much reproduces the original design:

Fencing Helmet Ear Grommet - show
Fencing Helmet Ear Grommet – show

The top washer goes inside the padding against your (well, her) ear, so I chamfered the edges sorta-kinda like the original.

There are no deliberate ridges on the central cylinder, but printing the parts in the obvious orientation with no additional clearance makes them a very snug push fit and the usual 3D printing ridges work perfectly; you could apply adhesive if you like. The outside washer has a slight chamfer to orient the post and get it moving along.

The posts keep the whole affair from rotating, but I’m not sure they’re really necessary.

Printing a pair doesn’t take much longer than just one:

Fencing Helmet Ear Grommet - build
Fencing Helmet Ear Grommet – build

It doesn’t look like much inside the helmet:

Blue Gauntlet M003-BG - replacement ear grommet - installed
Blue Gauntlet M003-BG – replacement ear grommet – installed

The OpenSCAD source code as a gist from Github:

// Fencing Helmet Ear Grommet
// Ed Nisley KE4ZNU December 2015
// Layout options
Layout = "Show"; // Base Cap Build Show
//- Extrusion parameters must match reality!
// Print with +1 shells and 3 solid layers
ThreadThick = 0.20;
ThreadWidth = 0.40;
HoleWindage = 0.2;
function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);
Protrusion = 0.1; // make holes end cleanly
// Dimensions
NumSides = 12*4;
$fn = NumSides;
// Useful routines
module PolyCyl(Dia,Height,ForceSides=0) { // based on nophead's polyholes
Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);
FixDia = Dia / cos(180/Sides);
cylinder(r=(FixDia + HoleWindage)/2,
// Parts
// Base on outside of liner
PostOD = 15.5;
PostLength = 8.0;
BaseOD = 26.0;
BaseLength = 3.4;
module Base() {
difference() {
union() {
for (i=[0:5])
// PolyCyl(PostOD,4.0,NumSides/4);
translate([0,0,(BaseLength - 4*ThreadThick)])
cylinder(d1=PostOD,d2=(PostOD + 2*ThreadWidth),h=(4*ThreadThick + Protrusion),$fn=NumSides/4);
// Cap inside liner
CapID = 12.0;
CapOD = 28.0;
CapThick = 3.0;
module Cap() {
difference() {
union() {
[CapID/2 + CapThick/3,0.0],
[CapOD/2 - CapThick/3,0.0],
[CapID/2,CapThick - CapThick/3]
translate([0,0,CapThick - Protrusion])
cylinder(d=PostOD,h=(PostLength - (CapThick - Protrusion)),$fn=NumSides/4);
// Build it!
if (Layout == "Base")
if (Layout == "Cap")
BuildSpace = 30/2;
if (Layout == "Build") {
for (j=[-1,1])
translate([j*BuildSpace,0,0]) {
if (Layout == "Show") {
color("LightGreen") Base();
color("LightBlue") Cap();