This helmet was designed by Weta Workshop to be used by the Uruk-hai Captain during the siege of Helm's Deep in "The Two Towers", but was never shown on screen. However, a mini version of it was released as a collectible, which is what was used as the main source of reference material.

Constructed out of EVA foam, the helmet is very lightweight and comfortable for wearing. The crest was assembled with styrene plastic sandwiched between two thin layers of foam for extra rigidity. After sealing the surface with a mixture of coffee grounds and Mod-Podge, spray paint was spritzed over the entire helm to give it a worn, rusted texture. Finishing included several passes of dry brushed acrylic paints.

A template was used for the base, but custom details were added to finish the helmet.