Traveling to a convention in another city is half the fun, until you start wondering how your helmet will survive the trip. A wearable helmet is bulky, has a painted finish that scratches easily, and may have motors and electronics inside. Packed the right way, though, it’ll arrive in exactly the condition it left. Here’s how.
Packing It So It Arrives in One Piece
The goal is simple: stop the helmet from moving, and stop anything from touching the finish.
- Wrap it first. Cover the helmet in a soft, clean cloth or a microfiber towel to protect the paint. Avoid bubble wrap directly on the finish, which can leave marks on some paints in warm conditions.
- Fill the inside. Stuff the inside loosely with soft items, like a T-shirt or socks, so the helmet keeps its shape and can’t be squashed.
- Close the faceplate. If your helmet has a moving faceplate, travel with it closed so it isn’t strained.
- Use a hard-sided container. A rigid case, a hard-shell bag or a sturdy box gives far better protection than a soft bag.
- Pad all around it. Fill the space between the helmet and the case so it can’t shift. Clothes from your luggage work well.
- Pack props separately. Arm pieces, shields and other props should have their own padding, so they can’t knock against the helmet.
Flying With a Helmet
Rules for props, sizes and batteries vary between airlines and airports, so always check your airline’s policy before you fly. In general:
- Carry-on is the safest option for fragile pieces, if the case fits within your airline’s size limits. You can keep an eye on it the whole way.
- If you check it, use a hard case with plenty of padding, and consider a “fragile” label.
- Allow extra time at security. A helmet in your bag may be checked by hand. Packing it so it’s easy to take out and put back helps.
- Bulky props, like full-size shields, may need to be checked or sent ahead. Check size and weight limits early. Our 1:1 Captain America shield, for example, is 61.3 cm across and weighs 5.3 kg.
Electronics and Batteries
Motorized helmets like our MK5 and MK17 Heartbreaker have a faceplate motor, LED eyes and voice control inside. Before you travel:
- Check how your helmet is powered and what your airline’s rules say about that type of battery. [CONFIRM the power source with the team.]
- Switch everything off so it can’t activate in your bag.
- Pack the charger in your carry-on, so you can recharge at your destination.
- Keep it dry. Never pack a helmet next to toiletries that could leak.
Unpacking and Checking It at Your Destination
- Unpack as soon as you arrive so the helmet isn’t left squashed in a case.
- Look over the finish for any marks or scuffs.
- Test the moving parts and lights. Open and close the faceplate and check the LEDs.
- Charge it fully before the event.
- Store it safely in your hotel room, on a table or shelf away from the window and direct sun.
Heading to your first event? Read Wearing a Helmet to Your First Convention for a full checklist, and when you’re home, How to Clean and Care for Your Replica Helmet.
Frequently Asked Questions
Can I take a cosplay helmet on a plane?
Usually, but rules vary by airline and airport. Check your airline’s policy before you fly and allow extra time at security.
Should a helmet go in carry-on or checked luggage?
Carry-on is safer for fragile pieces if it fits your airline’s size limits. If you check it, pack it in a hard case with plenty of padding.
How do I pack a helmet so it doesn’t get scratched?
Wrap it in a soft cloth, fill the inside with soft padding so it keeps its shape, and surround it with padding in a hard-sided bag or box.
What about helmets with batteries?
Airlines have rules for batteries. Check how your helmet is powered and your airline’s battery policy before flying.
What should I check when I arrive?
Look over the finish, test any moving parts and lights, and charge the helmet before the event.
