Helmet Planning | NXAKT Industrial Design

Research and targeting a new helmet project

Most helmet projects begin with a market segment clearly targeted. The competitors and the features set is mapped out. Other projects require that features be added and value increased for advantage in the market. We are able to provide a background of features and styling appeal that are available and determine the proper course of development for your brand or ODM offering.

Headform and size determination

The key to proper fit naturally is the headform, the shape of the interior of the helmet. It is vital to determine early in the process which headform will be used. As the final volume of the helmet is tied directly to the headform shape, the proper volume of helmet volume forms the proper basis for the following design steps. Headform shapes can be cut from Foam material to provide a working fit sample with an identical feel to a production helmet.

2D design, sketching, over-sketching

Using the information from the design brief and the results of the research, a series of concepts are generated in 2D by hand sketching, side views and details are sketched and illustrated. If a design is being evolved from and existing design, the designs may be drawn using photos as a reference. When an initial selection round is complete and feedback from the client is gathered, the next 2d round refines the concepts into a cohesive direction.

2D Envelope phase

Using the style lines and the headform plus protective foam thickness, a series of basic templates are built to guide the clay process. This keeps the styling development rooted in the proper size. A helmet that is too small during the styling phase will have to be scaled later in the process, this greatly affects the perception of a helmet design. The proper specification at this phase lets all parties perceive the design as close as possible to the final result.

3D Styling Clay

Wax and oil based modeling clay was invented in the automotive industry by Harley Earl over 60 years ago. The flexibility and speed at which shapes and surfaces can be explored is without equal. Industrial design and specifically helmets are often developed with a combination of traditional and digital methods, clay being the most common way to work on a shape. A helmet is an important physical shape, you wear it on your head. The sense of identity and social correctness are often enhanced and framed by the hair or a hat, getting the helmet shape right is critical. Both sides of the helmet are often worked in slightly different direction in order to explore styling options. Mirrored Photoshop images allow participants to evaluate each exploration.

3D CAD Modeling and Reverse Engineering

A finished clay model is digitized by a laser ranging system that results in a perfect “point cloud” that digitally represents the model. The selected side is mirrored to give symmetry and this digital representation is used to build the ideal CAD surfaces.
The process of creating surfaces from a point cloud is kn0wn as “reverse engineering”. The digital headform is either built or imported and combined with the surface model to place the new design correctly on the head.

Industrialization, engineering details and tooling consideration

The molding and engineering details of the helmet are key to keeping the costs in line with the client objectives. The numerous hardpoints, areas of technical connections are combined and developed according to the design. Strap attachments, interior venting, visor attachment and fit systems are some of the items. This step is done in cooperation with the factory, as the molding process varies and the the design is adjusted accordingly.

Certification and Meeting International Test Standards

Once a helmet has been molded, it undergoes a series of tests to insure that it passes that standards of the market it is being shipped into. ASTM, CE, CPSC and others. These test measure the forces experienced in a set of standard collisions. This is an iterative process to determine the density of foam, the placement of additional reinforcement, etc. To maintain the integrity of the design, it is best that the designer and the factory work together to resolve any issues that arise and make the proper corrections.