Visor test rig
Proving performance before launch
Putting our client in pole position
The brief
Entering a competitive new market
Known for its innovative snow sports helmets, the client saw an opportunity to enter the highly competitive motorcycle helmet market.
The goal was to create a helmet that improved safety, comfort and design, while giving riders something distinctive in a crowded category.
The ambition
Improving the next generation
Working closely with the client, we had already designed and refined four generations of helmet, shaped by rider feedback and wider safety research.
For the fifth-generation helmet, we focused on improving every aspect, from safety, comfort and aerodynamics to manufacturability, so the product could work better for riders and be made reliably at scale.
The design
Redesigning the helmet
Using advanced three-dimensional modelling, we redesigned each component and integrated new features, including:
- an embedded audio system that preserved aerodynamic performance
- improved ventilation that balanced airflow, comfort and noise reduction
- customisable design features, including spoilers and blanking plates, for a more tailored rider experience.
The development
Putting innovation to the test
Prototyping played a critical role in proving the helmet’s new features. We tested the ventilation system, visor mechanism and integrated audio system rigorously, making sure they met safety requirements and rider expectations.
To make production more efficient, we also developed a tagging system for every component. This allowed precise assembly while protecting the product’s structure and finish.
The result
A stronger market position
The finished helmet improved safety, comfort and style while giving the client a distinctive new product for the motorcycle market.
It strengthened the client’s position in a highly competitive category and built on the innovation already proven across its earlier helmet ranges.
