solarshield
Spring 2023
Timeline: 3 weeks
laser cutting + soft goods + Adobe Suite
Design a flat-pack/collapsible bike helmet made from a mixture of laser-cut materials that can minimize user assembly.
Solarshield is a flat-pack helmet* inspired by the solar rays of the sun.
*not a protective helmet
SOLARSHIELD features symmetrical foam strips on each panel, elastic velcro straps, and adjustable chin straps to conform around the head better.
CONSTRAINTS
Outer frame made of laser cut sheet plastics (styrene or PETG)
Exoskeleton
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Made of open or closed cell foam
Inner Padding
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Outer softgoods components for aesthetics or structure
Additional Components
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Not limited to webbing, cordage, velcro, buckles, etc.
Additional Materials
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Helmet must collapse when not in use
Collapsible
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Exploring existing collapsible helmets, origami methods, and other collapsible products.
MOODBOARD
IDEATION
↳ After exploring multiple concepts that allowed users to collapse or flatten their helmets, I ultimately went with this design direction.
PROTOTYPING
Rapid low fidelity prototyping using tracing paper and card stock. To finalize the design pattern and dimensions, foam, snaps, and webbing were added. Each component was later traced into Adobe Illustrator to be laser cut onto plastic.
MECHANISM
Refining the helmet’s collapsible mechanism and how it can comfortably and easily be worn on a user’s head. Some elements I adopted into the final product: living hinges, individual foam padding pieces, and velcro straps.
SOLARSHIELD
a flat pack helmet
ASSEMBLY INSTRUCTIONS
Gladiator vibes!
Finished helmets with the cohort!