Next-generation helmet
Putting our client in pole position
Proving performance before launch
The brief
Testing a new visor system
The client, known for its innovative helmets, was preparing to launch a range with a new quick-release visor system.
Before launch, the system needed to prove it could work reliably, safely and repeatedly under real use.
We developed a bespoke test rig to simulate repeated use, validate long-term durability and make sure the visor system met demanding safety standards.
The approach
Replicating years of use
We designed a custom pneumatic rig to replicate the forces and conditions the visor would face in use.
The rig ran thousands of opening and closing cycles at different speeds and loads, compressing years of wear into a short test period.
We also tested the visor system under demanding conditions, including high-speed airflow, sudden impacts and temperature changes. This gave us the data to assess performance, identify wear risks and refine the design.
Alongside mechanical testing, we assessed materials for wear, cracking and deformation over time. We also examined the quick-release mechanism closely to make sure it performed consistently after extensive use.
The result
Tested, refined and ready to launch
The rig gave the client clear evidence that the new visor system was durable, reliable and easy to use.
It also revealed where the design could be strengthened before release, giving the client confidence to launch the new helmet range.
