Bigscreen Beyond Face Gasket Base (Unofficial)

The face gasket that I got with the beyond put too much pressure on my nose. Also, the eye relief was too large, which limited my FOV. 

I designed this base and then boolean subtracted a 3D model of my face from it. With this 3d printed interface I now get close to the max possible FOV, and this gasket is significantly more comfortable. 

I took a 3D scan of my face using ScandyPro on an IPad. You should be able to take a 3D scan and boolean subtract that from this base. I found that I needed to scale my head's width to 110% for the interface to be fit me comfortably. You may want to grab the CAD files provided by Bigscreen, align that model to this gasket, and then use the eye assembly to help you find a good placement for your eyes. 

I used black Colorfabb's Varioshore foaming TPU filament. Warning, I don't know if this filament might have an additive that might irritate your skin, try this custom gasket at your own risk.

I found that using the following Prusa Slicer settings I was able to get the foam to be slightly squishy:

Filament Settings

• Use the default ColorFabb Varioshore TPU settings with following overrides:
  • Extrusion Multiplier: 0.72
  • Temperature: 225°C
• Keep in mind that if you are using a PEI print bed, you should use a layer of gluestick otherwise the TPU will stick too well to the bed and you will struggle to remove without tearing layers apart. 

Print Settings: Defaults w/ the following changes

• Layer height: .3mm
• Solid Layers
  • Top: 3
  • Bottom: 3
• Infill
  • 10% Cubic
• Support
  • Organic

Print so that the interface with the bigscreen points towards to bed. I found that using supports for the entire part, by floating the part above the bed 5mm, allowed my to take it off the print-bed without damaging any layers. In PrusaSlicer this can be done by adding a cube to the print, I made the cube 2x2x5mm. 
 

I used a Dremel with a polishing bit to make the interface smooth.

I glued in 3mmx2mm Magnets into the 4 corners.