100% Racing is the company that Dan Torkehagen, a talented industrial designer, did the design work for an outside consulting firm. The name of the product was picked by 100% and reflects the fact that the helmet has 25 air vents and channels making it the most ventilated helmet available. Read on to find out more of this project. Enjoy!

The 100% brand has always been synonymous with motocross and has been linked to many iconic moments that have built the roots and history of what is modern motocross. The brand dates back to the early 1980’s when the popular logo graced the factory racing equipment of the biggest names in motocross. The brand disappeared from the scene for a while, but has now been revived and is again taking a stand in the world of motocross. The progression from moto to bike isn’t such a huge leap and the natural connection between the different sports makes it possible to create products that will work for both. Since taking on goggles, gloves etc. 100% saw a market for helmet design and this is where we had the opportunity to create something new and interesting.

- Dan Torkehagen

Early on we focused on overall shape sketches based on the design research and direction that we had picked for the project. Once the client picked the shell shape they liked based on our concept sketches, we would then focus in on the smaller details as the mouth piece, visor etc. In the end I had to sketch all 4 orthographic views of the helmet to make sure everything was scaled correctly and to be approved by 100% Racing before moving on to 2D illustrations and tech packs.

We also were in contact with the manufacturer to get the correct specs for the EPS inner foam that would dictate a lot of the shaping of the shell, based on thickness specs for impact resistance. From there we had to sketch out some concepts for the inner lining, EPS venting and pad details that would go on the inside. Once all the design details were narrowed down and spec’ed out, we had to take the next step by transferring the 2D/tech packs to 3D. 3D would take a while, and we shared the files with the manufacturer that would produce the helmet to make sure it was built correctly for the molds etc. Since this helmet is made from carbon fiber it was crucial to make the surface shapes correctly due to the high labour intensive manufacturing processes. We had a few rapid prototypes made and a lot of back and forth to make sure everything was to spec before the final product was launched this year.

- Dan Torkehagen

Sketching mainly on paper with pen and markers for initial concepts. Then I would move on to Photoshop renderings, 2D illustrations and tech packs in Illustrator, and finally cad model made in Rhino 3D. The biggest challenges were the carbon fiber that is somewhat difficult to work with. Parts of the design of the helmet needed to be softened to accommodate the glue process of the helmet etc. Also being aware of the Consumer product safety standards of bicycle helmets, the EPS references for thickness etc. was very important and can dictate a lot of how the outer shell is shaped as well. Once we had a working sample of the helmet, there were a lot of great rider feedback, which we used to update the final visor and the size of the helmet before moving to production.

- Dan Torkehagen

About Dan Torkehagen

Dan Torkehagen was born in Oslo, Norway and has lived a little around the world. He spent a few years in England and Taiwan, worked a little in Hong Kong and ended up graduating from Arizona State University, Herberger Institute for Design and Arts in 2008 with a BSD in Industrial Design. He moved out to Los Angeles and started working for an accomplished full service design studio called Mage Design. He got the opportunity there to work with many great industry-leading lifestyle brands as for instance Burton Snowboards, 100% Racing, Fox, Skullcandy, North Face etc. and it really offered a unique environment for him to practice his multidisciplinary skill sets. Currently, he works as a freelance product designer and illustrator, and spend most of his time in Oslo and back and forth to Los Angeles as much as possible, trying to maintain the great connection he got to the city and the people there. You can find more of his works on his Behance profile or website.