Downhill Skateboarding Helmet

This Downhill skateboarding helmet is a project collaboration with current World Champion Downhill Skateboarder Diego poncelet, 3x World Champion & Industrial Designer Martin Siegrist and Aaron Skippings.

The project was to develop an aerodynamic helmet that is capable of breaking the current speed record of 91.17mph - held by British downhill skateboarder Pete Connolly.

The process started by 3D scanning Diego in various positions to build up a 3D model of his body so that we can then design a helmet that fits perfectly to his body shape while creating as small amount of drag as possible.

Once the design was finalised it was then 3D printed in 6 sections and bonded together to make a pattern. A split mould was then taken from the 3D printed pattern.

The helmet was manufactured using the wet lay process and then vacuum bagged for consolidation. It is constructed using a mixture of carbon and carbon Kevlar laminated with epoxy resin. Once finished the helmet, Including the safety inner helmet, weighed just 900 grams!

The project was completed relatively quickly due to a tight deadline as we were scheduled for a wind tunnel test at the Hepia wind tunnel in Geneva with Swiss TV. They were along for the ride to interview and document us. The results were extremely positive and a speed record attempt will be happening in the near future!

Credit Images - Joan Sanso.

Credit 3D Prints - Edwin Van der sar.