I usually research something before posting, but I thought I’d just throw this out for discussion. Here’s Geordi’s VISOR from the pilot.
Here are my observations and guesses. Tell me where I’m wrong!
It looks like an aluminum band was cut out for the front surface and bent into a curve.
The top and bottom plates are…wood…plastic?? They have a lot of marks on them for some reason. Oh wait, it reminds me of how rubber stunt props look. Is it rubber?
The grill is relatively soft brass rod that has been cut, somewhat distorting the rod and smooshing the crimped ends.
The rods have been soldered to the metal front piece, giving them a flared-out base where they connect.
The insides of the band have been hollowed out to make room for the lights on Geordi’s temples. This is only needed for shots where he removes it.
The inside of the bottom plate looks to be dark. To cut down on reflections and make his eyes hard to see?
The shot of him wearing it has some light-colored obstruction towards the sides of his eyes, behind the grill.
Is there a dark colored scrim behind the front of the grill in this shot?
The circles of the VISOR situated over his temples are holographic tape.
I know there are later versions of the VISOR, with notable differences, but I wanted to focus on this initial version first.