We will convert the curve boundary as a Surface. Rebuild the surface to degree 6 surface in U & V directions. We will move the CVs to flex the surface. And later extrude the Surface to convert it as a Solid geometry.
To fillet the Edge, we will use a different approach. Let’s pipe the Edge, rebuild the pipe surface to simplify the complexity. Use the pipe to trim the edges and bridge the gap with BlendSrf with desired continuity (G2).
We will add two parallel curves to add the front design feature. After splitting the front surface patch, we will move the central control points. Finally bridge the surfaces with surface from Sweep2 rails command. Make sure to select the curvature continuity criteria to create a smoother transition.
We will use a mesh geometry to approximate the mesh intersection with the Headset. This will give us a rough splitting curve. We can recreate a clean cutting profile for the forehead, cheek and nose contact points.
For the internal part of the VR Headset, we will use the outer shell shape and offset the overall shape. Use similar splitting profiles for the design features.
To model the Headband part, we will draw a rough sketch based upon the reference mesh. We will draw a cross sectional profile and use Sweep1 command to create the 3D geometry.