I've designed a clip to modify to your hearts desire. It's just the base clip that has been tolerance tested and works very well. Modify it to your hearts desire.
.1mm layers
50% Infill
Supports for the arch of the hardhat will help.
I also experimented with .2mm layer height and it works as well. Although the chamfers transition is more noticeable.
The author marked this model as their own original creation.