Fly Racing WERX Helmet
Project management, Product Design, CAD,
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 WERX helmet.
The Werx is a cheaper helmet than the Fly Formula. We needed to design smaller RHEON parts and cheaper construction methods.
This was the first RHEON part integrated into a fabric helmet Liner. This presented new challenges of how to fix together the two parts without greatly increasing the cost of manufacturing.
Design for airflow
One part of the design exploration was to make sure the protection did not affect the airflow of the helmet.
I designed a part that used channels that flair out, maximising the surface area, whilst keeping space for air.
These flairs had the secondary benefit of having a gradient of force buckling. As the force increases, more of the structure buckles, allowing for more effective acceleration damping.
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