For our design, the visor is laser cut from a 500 micron polyethylene terephthalate glycol (PETG) sheeting (Adarsh Australia). PTEG is selected for its clarity and light transmission, impact resistance, economical, readily cut with a laser thus achieving highly reproducible geometry with good tolerances. The frame is made of a forehead custom‐shaped flexible polyurethane foam (Dunlop Foams C.A.S. Number: 9009‐54‐5), which is fixed to the visor using a food‐grade cyanoacrylate glue (Locttite 435, Henkel). The glue is applied using a custom‐made jig ensuring a reproducible amount is applied each application. The suspension system is circumferential with an elastic strap secured to the visor with a button through laser‐cut holes. In order to fit the headlight, the binocular optic was flipped up and the distance anterior to the forehead measured (40 mm) for an extended foam projection (Figs.  1a  and b).