We made this Daft Punk hat for Anime Boston where it will be making its public debut next month.
The shell is vacuum formed styrene, formed in 4 sections (front, back, ear pieces)and pieced together. The "visor" is vacuum formed smoke tinted acrylic. All the shell pieces were formed over hand-sculpted bucks, which were carved out of a dense rigid urethane foam. The visors (front and rear) were formed over bucks which were sculpted to shape out of foam, then a mold was made of those, and a new buck was made from those molds out of epoxy surface coat & epoxy resin. The extra work put into the vac-form bucks for the visors was because any imperfections in the buck would show up on the transparent finished piece so they had to be perfect, whereas any imperfections in the vac-formed pieces that made up the frame could be filled and sanded before painting.
The lights are 5MM LEDs (175 of them) powered by 2 9v batteries.