KitKat Break Helmet

Bespoke Costume Prop Engineering for “The KitKat Break Helmet”

MACHINESHOP fabricated the ultimate practical custom asset for KitKat’s high-profile “Break Helmet” advertising campaign. Developed in partnership with global creative agency VML, this high-fidelity lifestyle piece was inspired by the advanced head protection used in Formula 1 racing. The creative brief required our workshop to engineer a functional, camera-ready helmet designed to jokingly protect chocolate breaks from daily workplace distractions.

The embedded videos showcase our intricate model-making processes, precise electronics assembly, and the component testing required to deliver a polished, immaculate outer shell finish under studio lighting.

Advanced 3D Printing & Component Model Making

Replicating the intricate aerodynamic geometry and tight physical tolerances of a professional Formula 1 helmet requires a detailed multi-stage fabrication pipeline. Our workshop team focused on material accuracy and structural finish to ensure the prop looked entirely authentic:

• Industrial-Grade 3D Printing: Utilizing high-resolution 3D printing technologies to output the interlocking modular components of the helmet chassis with razor-sharp precision.
• Precision Surface Smoothing & Modelling: Executing multiple rounds of hand-sanding, filling, and structural modelling to eliminate artificial tooling lines, making the asset completely macro close-up ready.
• Integrated Mechanical Visor Elements: Engineering low-profile manual pivot tracks to allow the tinted front faceplate to slide up and down predictably across multiple takes.
• Flawless High-Gloss Paint Finishing: Applying automotive-grade base coats, brand-accurate Nestlé red decals, and a premium high-gloss clear coat to replicate a genuine protective racing composite shell.