• how would you make them look (within the constraints of materials used and cost)?

    Well, I would just forget about that aerodynamical look with tons of different colors and make them in uniform matte (why are they always glossy?) colours.
    Just an idea I'm not a helmet designer. But it should be possible to make something that's looking ok but still light and not too warm, no?
    Something between these that look great but are to warm:

    And this that is light but looks horrible (IMO):

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