Portfolio/ Helmets/ Urban Jet Open-Face Helmet
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Helmets

Urban Jet Open-Face Helmet

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Lightweight Urban Design
The helmet was designed around a lightweight open-face architecture that provides an excellent balance between rider comfort, visibility, and everyday usability. Its compact proportions make it ideal for daily commuting while maintaining a premium visual identity.
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Manufacturing-Ready Construction
Developed using Design for Manufacturing (DFM) principles with injection moulding-optimized geometry, controlled draft angles, clean parting lines, and simplified tooling strategies to enable efficient large-scale production.
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Integrated Visor Mechanism
The visor and hinge assembly were designed as a cohesive system that blends naturally into the shell, improving aesthetics while simplifying assembly and supporting smooth visor operation.
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Unisex Premium Styling
The clean minimalist form, balanced proportions, and neutral design language create a versatile product suitable for both male and female riders. The styling remains modern, approachable, and commercially attractive across a broad customer base.
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Production-Oriented Engineering
Every exterior component, mounting feature, and assembly interface was engineered for repeatable manufacturing, efficient assembly, and long-term product reliability while maintaining premium fit and finish.
Open-Face HelmetIndustrial DesignInjection MouldingDFMProduct Development
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How it was made

Sketch to shelf.

Design render
01 / Design

CAD & DFM

Full parametric model, manufacturing constraints built in from the first surface.

The engineering behind it.

The goal of this project was to create a premium open-face motorcycle helmet tailored for modern urban commuting. Rather than relying on aggressive styling, the design focuses on clean surfaces, balanced proportions, and timeless aesthetics that appeal to a broad consumer audience.

A compact shell profile reduces visual bulk while maintaining generous rider visibility. The integrated visor system follows the natural curvature of the helmet, creating a seamless appearance and minimizing unnecessary exterior components.

The helmet enclosure was engineered using Design for Manufacturing (DFM) principles, ensuring compatibility with injection moulding processes through optimized wall thickness, draft angles, and tooling-friendly geometry. Assembly interfaces were simplified to improve production efficiency and consistency.

The final design delivers a refined combination of comfort, manufacturability, premium styling, and commercial readiness, making it well suited for large-scale consumer production.

01
Draft Angle Analysis
Every face verified for clean ejection.
02
Parting Line Optimisation
Positioned to minimise slider actions and tooling cost.
03
Wall Thickness Mapping
Uniform walls for consistent fill and no sink marks.
04
Ejection & Cooling Layout
Ejector and cooling-channel strategy defined for the toolroom.

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