This particular neck band design required some tricky lofting profiles that pushed the SolidWorks modeller to its limits at the time in 2004. The issue was resolved with the assistance of the SolidWorks development staff in Boston that worked through the problem with us. This was through contacts that were made having attended SolidWorks World 2002 & 2003 in the USA.
The base geometry was determined by using a trace-over technique from similar headset geometry that was photographed; to speed the development. See photographs 3 & 4. Altogether, this technique and the SoildWorks 2004 Lofting worked very successfully.