In the world of product development, the journey from a concept in a CAD environment to a tangible, usable product is filled with innovation and challenges. Our latest helmet design journey encapsulates this process, showcasing the intricate balance between design, functionality, and manufacturability. Here’s a closer look at how we brought our vision to life, from SolidWorks sketches to the final product ready for adventure.

Prototyping: A Tale of Iterations

The prototype phase was critical in transforming our CAD models into reality. This process was not without its iterations, each teaching us valuable lessons about design and manufacturability.

• Adjusting Wall Thicknesses: Early on, we faced the challenge of ensuring our helmet's walls were thick enough to meet manufacturing standards while remaining as lightweight as possible. Thinner walls are more lightweight, but, come at the cost of part warpage during fabrication. Finding this balance required several iterations, tweaking the CAD files, and verifying the manufacturability with our vendor.
• Repositioning Screw Boss Mountings: The placement of screw bosses, critical for assembly and structural integrity, needed adjustment. Original locations led to assembly difficulties and potential stress points. Iterative redesigning and testing resulted in optimal placement for both manufacturability and product longevity.
• Sizing the Shock Cord: A vital component of our helmet's design was the shock cord used to hold sections together. Getting the tension just right—to ensure a snug fit without compromising comfort—required trial and error with various cord lengths and elasticities.
• Adding External Features for NVG Retention: To minimize mounted goggle movement and ensure stability, we added external features specifically for shock cord retention. This design tweak was crucial for dampening movement during activities like walking, running, or tactical operations.
• Sourcing Custom Tensioning Knobs: A particularly challenging aspect was finding the perfect tensioning knobs for adjustments. A partnership with an external vendor allowed us to develop knobs that not only met our functional requirements but also matched the aesthetic of our design.

Bridging Design and Manufacturability

Transitioning from CAD to fabrication involved close collaboration with our manufacturing partners. Communication was key in ensuring that the design nuances were understood and accurately implemented. This stage highlighted the importance of selecting the right materials, understanding fabrication limitations, and being open to adapting the design to meet those constraints without compromising the product's core design, integrity or functionality.

The Final Product: A Testament to Innovation and Collaboration

Seeing our helmet go from a SolidWorks file to a tangible product was immensely rewarding. Each iteration, each challenge, and each decision along the way contributed to a helmet that we're proud to bring to the market.

This journey from CAD to reality underscores the complexities and rewards of bringing a new product to life. It’s a testament to the power of collaboration and the importance of adaptability.

We invite you to explore the night.