3D development of the 4Forty was done in clay for its ability to efficiently and quickly explore shapes physically. Early on in the project ventilation was made a priority, so uniquely shaped vent holes became integrated into the graphic design of the form to meet testing requirements. Considerations along with the sculpting of the 3D form as well as very purposeful part line designs allowed this helmet to be manufactured without internal roll cages, a feat with large vents like this design. This also cut costs and allowed a more feature rich helmet in this price segment as well.