PRODUCT DESIGN
Helmet Liner
While working for D3O (impact protection company) i was assigned to lead and design a platform technology that can be adapted and pass various standards for sports helmets. The initial target was american football helmets, at a time were the US congress was considered restrictions or banning tackles, due to numerous cases of players getting concussions and permanent brain damage. The final product had to pass and be certified according to the NOCSAE standard.


Issues with existing products
- Foam of different thickness and stiffness is used in the same helmet as the human head is not a perfect sphere and impact requirements are different in each area.
- Open cell foam incubates MRSA bacteria, some resistant to antibiotics. Several hi profile players contracted those over the resent years.
- Fabric and open cell foam are hard to clean. Helmets become smelly and unpleasant.
- Complicated/expensive assembly (manual) and big inventory of parts.
- High tooling cost to produce all the parts.
- Time consuming reconditioning (repair).
Design Solution
During this project a new material was created to pass the NOCSAE standard and I also developed a process of coating the liner with TPU film in the tool. The performance had to be similar in any location but as the helmet has irregular shape, I had to optimise the volume of material in each area taking into account fit, breathability, comfort, weight and material properties. The result is aesthetically pleasing and looks simple, but required an immense amount of testing to fine tune.