While at Specialized Bicycles in my early career I was able to work on a broad range of product categories, including Helmets. Working with their helmet development group, I worked on two ground-up helmet designs, the ‘COVERT’ and ‘DISSIDENT’ helmets.
In addition to these two platforms, I also developed several key technologies and solutions outside of the actual helmet itself such as the ‘Tri-Fix’ strap system, as well as development and implementation of graphics concepts.
As with all projects, i started both the 'DISSIDENT' and 'COVERT' projects with a heavy amount of research that was focused on the Market, Key Competitors, and the needs of the User.
Above shows some of my early-on competitive market research for the DH Helmet Project. My research spanned both MTB and Power Sports helmets, looking for new technologies, trends, materials, construction, and graphics.
In addition to market research, I tapped into inter-office Peers, Consumers, and Professional Athletes alike by creating the below questionnaire. For both helmets, this layout proved invaluable as it got concise feedback on the primary competitor helmets that we were benchmarking, helped establish insight into the wants and needs of each user, as well as expectations of Pro Athletes vs. Elite or Enthusiast Consumers.
Research Phases completed we had a good direction on what we were looking for, and where we wanted to take both helmets.
With the Covert, I decided to focus on radial vent patterns based on fan/turbine blades, inspired by the rotors of High-Performance Attack Helicopters like the Apache and Comanche. I started off with larger, chunky openings, and quickly ideated and developed them into a theme for the helmet.
For the DH Helmet, I began with concept sketches and renderings, exploring new concepts like ducted vent ports that funnel air from an intake on the visor through a flexible bellow into the shell of the helmet. Other innovations I looked to bring were wired and wireless audio support for both music as well as communications to keep track of your buddies in case someone ends up in the bushes. In a worst-case scenario, we also looked to integrate inflatable helmet removal in the event of a neck injury.
Many other innovations came about while I was involved with the helmet group. I developed numerous concepts for strap fixuring, as well as pioneered the Specialized Tri-Fix solutions used to this day.
After my initial concept sketch development on 'DISSIDENT' I began creating a half clay model that would serve as the basis for my 3D exploration. Unfortunately I did not retain any documentation of the model making process for this project. It was done using automotive clay as a half-buck, placed against a mirror. Within this model, I also did extensive studies for interior foam channeling for ventilation and cooling. It was used in order to gain Pro-Rider feedback and aesthetic direction to help guide future development.
For the 'COVERT' 3D development, after the initial vent exploration and additional sketching, I jumped into model making to finalize the design. Starting with a competitor helmet, the shell holes were filled with bondo, the drip line modified, and new vent holes were sculpted in to the existing shell to create the desired aesthetic. On top of this (or rather, inside) I also filled in the holes of the foam, and re-sculpted it to create a fully realistic representation of the helmet that could be both worn and ridden in order to confirm a proper fit, function, and aesthetic.
Once approval was gained from key decision makers, we moved forward with engineering development. Surfaces and thicknesses were scanned and I worked closely with the staffed engineer to maintain aesthetics within the final design.
I also went on to develop the Tri-Fit strap solution, as well as the Pad Kit that went into the helmet as well.
Afterwards, Tech Packs were created not only for vendor relations in manufacturing, but also for graphic development.