Snow sports production work from 2012. Ski and snowboard crossover helmet. Polycarbonate thermoformed in-molded shell with BOA adjustment system.
This was the evolution of the previous model helmet that followed a clay-to-digital workflow. Clay sculpting of the prototype helmet shapes had been an integral part of sport helmet development. Although surfacing tools had been in place for a decade at least, sports companies did not trust them 100% yet. Especially for helmets where very subtle variations are fretted over, akin to phrenology. Confidence in the fidelity of the surfaces throughout the previous hybrid workflow, digital-to-clay-to-scan-back-to-digital, allowed us to set this following model up differently.
This helmet model development was digitally based from the start, specifically because of the tools and workflow made possible by Rhino.
Once a vent design was selected, roughed into the CAD shape and then renders painted over to maintain a sketch mindset without sweating the finer surface details during review.
Deep dive into the production surfacing, as minimal as possible given the details and transitions, molding considerations, venting and hardware, and fit system integration.
