Adidas Techfit & Zero
Product design, Generative design, 3D visulisation
Fly Racing had a close colaborative relationship with RHEON Labs. I worked on multiple helmet projects, for the Fly Formula, Fly Werx, and 2 unreleased helmets.
I was the Project manager and Design lead for the RHEON part of the Fly WERX helmets.
Designed, prototyped, tested, optimised and developed production methods for the Fly WERX helmet. Over 50,000 helmets have been sold.
My design and optimisation process improved the helmet performance by 20%. An extraordinary number for a helmet design.
I also optimised the production process for the RHEON parts, and onboarded the production process for a new supplier, saving the company over $200,000.
Fly Racing WERX
I was the Project manager and Design lead for the RHEON Inserts for the Fly racing helmet.
Design for airflow
I tuned a custom 3D printer to print extremely high fidelity parts using pellet based flexible thermoplastics.
Prototyping
I tuned a custom 3D printer to print extremely high fidelity parts using pellet based flexible thermoplastics.
Testing
The design was tested on the RHEON Labs helmet testing rig. The performance of the helmet was shown to be improved by 20%.
Helmet Liner design for manufacturing
I worked with Fly Racing's manufacturer in indonesia, to develop the best manufacturing for the fabric liner.
I prototyped with fabric work.
Helmet Shell Design
Working with the head of design at fly racing, I designed and prototyped the