How A Road Bike Helmet Is Designed - Behind The Scenes With The NEW Bell Zephyr
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- Опубликовано: 30 авг 2016
- So, what exactly is 'THE THERMINATOR'?! We went to Bell Helmets to see their NEW Zephyr helmet and find out...
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We've been wondering exactly how a bike helmet is developed for a while. When you think about it, there are a tonne of things that a helmet needs to achieve. Safety, comfort and style are just a few of them.
How then, does this product development go? Well, we were lucky enough to be invited to Bell Helmets to find out all about their new Zephyr helmet which features a few new bits of tech including dual shell construction, a sweat management system (thank them later Si!), MIPs and wattage saving straps.
You know the score - check the video out, hit share, hit the thumbs up and let us know what you think down in the comments!
Thanks to Bell: gcn.eu/BellHelmets_
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Guys, just wanted to say thanks for the content, yesterday I picked up my first bike in 20 years, I'm 43 and not fit.....having found your channel I have spent a few hours updating myself with your hints and tips....I must say your presentation is fantastic and I have learnt so much just by watching
Thanks Adam!
This guy comes across like he's making it up as he goes along
Great video, will probably show this to my GCSE design students so thanks for the lesson content!
Awesome video! It's always good to see the behind the scenes stuff.
"This particular mold has a lot of different parts to it"
*proceeds to remove 4 parts*
It was 5 right? I know a guy who used to work for a company that's main source of income was taking a prototype and designing a mold. A lot more goes into it that the number of pieces. Something about the fewest/simplest parts and the fact that resin must be still be able to flow into the mold easily. I'm in no way an expert, but there you go anyways.
That shot where Si is caressing his face and new helmet in slow-mo was hilarious :D
How to design a helmet = not really
Two piece, progressive layering = 2 mentions
Graphics and how cool a helmet has to look = 100+
Aerodynamics doesn't get much consideration either. Really, if straps are that much of a loss, how come no one makes an ear fairing? Unless the object of aerodynamics is to disrupt aeroflow, most helmets look really dirty to me. They don't even seem organized to ingest air effectively.
And what is this talk of EPS lately? Its "Expanded polystyrene", and it ain't changed much in 40 years.
I can't take this guy serious with that hat.
I know right? -_-
welcome to California
but why wear a cap indoors at all??? and he's not even bald...does he also walk around with an umbrella sometimes?
+Bris Focus it's SoCal, we wear ball caps and flip-flops EVERYWHERE. I even have a pair of nice leather flip-flops for going out to dinner, aka California formal.
That's how we live here in California hats and sandals/flip flops
How can the guy design pretty helmets and not being able to pick a cap that looks good on him ?
Cali style
ouch
Absolutely love Si! What a character.
Great video, like Spearfisher1970, been struggling with finding my next helmet (long overdue). Having used a Bell helmet for 4 years, I believe I have found the one! Thanks for a fantastic video, big ups to Bell for inviting us into their inner workings. Feels like I know them better now, and trust the product more as a result :)
Great vid GCN. Thanks!
Incredible stuff, a fully grown man wearing a snapback. Thanks for sharing.
Hope you enjoyed your time in the Santa Cruz area, Si. We've got some awesome roads around here.
This was a really interesting video. I enjoyed hearing an explanation of the processes involved in creating a helmet. This video also tore down one myth that anti-helmet people have been saying: helmets are only tested/designed for top down impact. This helmet had design features to deal with rotational forces. We also saw a kind of "skid" crash test that simulates what one might experience going over the handlebars. Rotation on the skull as far as I understand it is the easiest way to get a concussion. Good to see Bell really is taking safety seriously.
This is one serious helmet, it's a lil heavier than the Giro Synthe. It's just as comfortable and more adjustable than the Synthe. It's a really cool looking helmet once you actually see it up close in person. This is my new favorite helmet now.
love that bell cap that dude was wearing. thats awesome
I just bought one - finally - to replace an equally-vented Giro. Looking forward to the rain going away and testing it, but here in my living room the MIPS fit feels like it will automatically be more comfortable from a friction- and pressure-point standpoint.
Very impressive video, GCN! So neat. My current helmet is a Bell, and I'll be looking to replace it with another soon. Might as well be another Bell (if I can afford this level of helmet - but for south Florida, the cooling capability of a helmet is key).
Thanks!
That was very considerate of them making it in GCN colours to match the kit.
This is probably the most useful video you have ever made. Well done.
Thanks John
That's a good looking lid. Si wore it like a pro
Interesting video and it made me realise just how much work goes into designing and making one. What I also found interesting was that unlike the new Bell helmet other makers seem to be making helmets with a fuller design. By that I mean that there seems to be more protection around the neck and rear of head. At least there's more plastic. In fact BELL seem to have designed a helmet based on the original 60s net helmet. Be interesting to see whether other makers do the same.
Looks like they pulled the design guy to explain the engineers work :P
Guy has a Cintiq and sketches everywhere on his desk, very cool to see, I think Si kind of tried to talk to him like an engineer haha
Most unique, more unique, completely unique? Argggh!!!!!
Great video guys! Would have been cool to see more of the the safety benefits of this design in action. I think I would only really buy an expensive helmet if I thought it would significantly reduce injury in a crash. Design IMO comes second but sometimes dictates the price tag. Keep up the great work :)
great video !
Helmet fits and looks great
Was intrigued by this helmet but don't really like how it fits the host, the usual Protone seems to fit much better, less bulky and mushroom head shape.
9:00 This feature is awesome
Great VID.. Liked the Joke about sweat....
@GCN this was a fun video, nice to see a quick behind the scenes. While it was a nice to learn about the aesthetic aspects, aero qualities, and heat dissipation tech, I would still like to know about helmet effectiveness for impacts, which is the only reason to wear a helmet in the first place (otherwise we'd be better off going without and being cool and aero with a skull cap or similar item). The video showed brief shots of helmet impact testing, but you didn't talk about that at all. Too bad, that. #torqueback
Who fell asleep getting this video out? Didn't anybody read the poster on Muller's wall?
Nice video though... I can't wait for a chance at winning a Zephyr from GCN.
I have the Gage and it's by far the best i've used.
Si's Aeroad, Dan's new Factor, Tom's brand new Trek. You guys should redo the GCN presenter bikes video!
That looks a ton like the Santa Cruz Mountains, are you in the Bay area??
My helmet strap vibrates at 45mph. It's a great signal to me without having to take my eyes off the road to look at my display.
Some where in the SF Bay Area. Does this shop also make motorcycle helmets?
Looks like a buget copy of the Giro Synthe
Yeah
not so budget.... :L
I disagree.
Not a surprise since Bell owns Giro.
Same company.
you should do a review on the sena helmet.
Hey Steve, how much your helmet cost?
Steve: About the price of two Walmart adult bike.
The Coolest Dummy in the video had my aero helmet! Same visors to.
nice helmet!
Bell starpro gets very hot, supposed to be combination aero and ventilated but it seems like the vents don't work that well.
Hey GCN, are you guys still working with KASK helmets?
Hey Robert, yeah we are.
Given the previous videos I've seen on the channel, I would have expected Matt to be the helmet expert or at least have the most experience with their reason for existence..
Fair point.
Could we get a comparison of fit between helmet brands? I know that my head makes Giro helmets look wider than normal and Cannondale fit closer to the shape of my skull.
This guy makes me want to buy any other helmet other than a Bell
awesome
The Bell logo in the front part makes it look like a cheap helmet, not the fact that it's Bell, just the fact that the logo is in the front, and seems to break the flow of the design
Nice video 📼 but by the way 😊. Caps or capelino 😎
nice hat game Si
Picture quality got so much better, what did you guys do with it?
Hi guys! What's the deal with mesh panels in the front vents of a helmet? I bought a cheap helmet from Aldi several years ago and it had mesh across the vents that stopped flies/bees/wasps getting in, but recently purchased a much better helmet from Giro that doesn't. And by the look of it, none of the 'pro' helmets you feature have any such mesh? Is there a good reason for this? Aerodynamics? Personally I was annoyed recently that I had obeyed Rule #37 while attempting a Strava segment in my village: a large bumble-bee flew into one of the front vents of my helmet and proceeded to buzz very loudly as I was in the last few metres of my uphill 'sprint'. I undid the helmet strap and ripped it off my head to release the bee, thus flinging my sunglasses across the street. I still managed to finish the segment, mind. Went back and collected my sunglasses (largely unscathed) and later discovered I'd got the KoM into the bargain! Still puzzled about the mesh, though, as it would have prevented the bee from entering in the first place... #askgcn #torqueback
I'm guessing looks along with ventilation in really hot locales. If you want mesh these days, try looking for a skull cap with mesh panels. I've got a Pearl Izumi summer cap that's mesh and keeps my forehead completely dry. Smith's Overtake also covers the vents in a neat honeycomb material. Or just get the Kask Infinity like GCN :P
Still not sold on MIPS. Beside I bought a new Kask Protone this summer so I off the market for a new helmet for the next few years and unless I crash.
I'd take one
i always though Bell's design(aesthetics wise) was inferior compared to its competitors but they did a pretty good job this time. but still i'd go for giro or specialized.
I really hope Bell make a helmet called "End" - you know - the Bell End...
Too bad for Si that this helmet doesn't take the sweat from the armpits. Might be something to look at in future models.
i cant believe no one has made any sort of joke about simon sitting down with his helmet between his knees. lol.
on another note, i had always thought of Bell as being at the lower (supermarket) end of the helmet game with the likes of kask and giro being more of the norm. Looks like i may have to re evaluate my thoughts.
out of curiosity. was this a production-ready colour combination, or was it created especially for GCN colours?
I am sure this has been asked before, probably even on a previous show, but how often should I replace my helmet? I've been hearing a variety of different answers, from 1-10 years. I realize your sweat erodes the inside of your helmet (or so I think), so is there a certain limit to how long you should keep your helmet?
+Haeral Thank you! I've had my helmet for roughly 3 years now. Glad I don't have to worry about swapping it out for another anytime soon!
Have you crashed? replace
Is your helmet worn (deep dents, cracks, ..)? replace
Do you have any concern about the safety after even small impact? replace
Is you helmet foam soft (it gets softer over the time significantly)? probably replace
In my opinion 5 years is reasonable amount of time.
Thank you guys! I'll probably give my helmet a couple of more years!
Don´t you have an idea where I could find that article? It sounds really interesting to me.
you replace it after one impact
Will you give some of these helmets away in an unboxing video?
didn't know curtis keene worked for bell... :P
Gah. I just got a KASK mojito this summer. And for sweat management I just wear a cap.
Was the real "Dir of Product Creation" on vacation?
"...it's really complicated with lots of parts...." Really?
Anyone else here for CDT work? Good video btw
Is that the end of the kask kit then?
Hey Dom, no not at all. We wear Kask helmets every day but we also want to show you other cool stuff when it comes out.
+Global Cycling Network It's good to see you not just sticking to sponsors, although they are important, keep up the good content!
I think my next helmet is going to be a BELL helmet.
is it just me or does Si look a bit like Toad from Super Mario with that helmet on?
Crikey! Si testing a non-Kask helmet! He must have bumped his head! #productplacement 😈
Errr, I'm not certain as I might have got mixed messages, but I suspect Mr. Muller likes Cadel Evans going by his wall art.
Yeah, Cadel won the Tour de France wearing a Bell helmet. Crucially though he wasn't on the mood board!
cool...but bell really needs to update their logo for more coolness
no offense i think the kask helmets look sick
"Allows us to create what we call a structure", he says. Yeah, everybody else calls that a structure, too. That's what the word means. Conversely, when you say that you're "litererally taking two separate components and joining them in a way that's much more meaningful", that is not what "meaningful" means.
He says that safety is the absolutely most important thing, but then says that the "upside" of the dual shell thing is that it looks cool and you can put good graphics on it. What's the downside? That it's safe?
Sorry, but this guy is just spouting garbage.
And, by the way, when he says he won't go into too much detail about how the Therminator works, it's because he doesn't know. If he knew, he'd know the difference between a thermocouple (a thing that measures temperature) and a "thermal couple" (which doesn't actually exist).
Wow never been this early
Same!
Handsome roads, there. Do I spy redwoods?
Yep, Santa Cruz's finest.
Si is A head above the rest.
Simon rubbing his helmet again!
When I first saw this helmet I thought it looked just like a Giro helmet.
Not a surprise since Bell owns Giro.
why is kask no longer a listed sponsor ? 2 weeks ago it was.
Kask is still our helmet partner but we want to show you other products that we think are cool too.
So it's a Bell Giro Foray?
Looks like they lost KASK's sponsorship?
We're still working with KASK - you'll see their helmets in our regular videos, but we'll continue to work with brands and products that we find interesting.
is that a fingernail scratch or something a bit more sinister on your neck at around the 5.50 mark?
I hope the California heat wasn't too bad. I'm getting kind of tired of it...
that slow mo of Simon was just too much for me.
I smell sponsoring.
Three points: 1. If something is unique, by definition it's one-of-a-kind. There is no such thing as "extremely unique". 2. I believe the devices are correctly referred to as thermo-couples rather than thermal couples. If the creative dude doesn't know the correct name for the device I start to doubt HIS understanding of how it works. 3. Based on the way the creative dude has dressed himself, he is not representing his brand particularly well.
#TORQUEBACK Does the rolling resistance of a tyre increase, decrease or remain the same as it gets worn?
The price vs performance from lowest price to highest is BS. Since coming back into the sport after ten years I have realised that the golf crew need to go back to golf :0 Either that or the price of lycra is more than silk......
Yeah I know the feeling mate. Helmets are a real eye opener. POC helmets are beyond ridiculous at £200 plus. They are literally plastic and foam.
Looks like someone had been shopping at Rapha
now then- silk cycling shorts... theres an idea....
Since you know how to make cycling apparel so well, why don't you go start your own brand that sells premium product for bargain prices?
Hey Emmet, cycling's cool. You can have fun, ride fast and stay safe all on a budget, you don't have to spend loads of money. However, that doesn't mean that expensive products are B.S.. If it takes a team of highly skilled people several years to develop something, and actually producing it is also costly, there's going to be a high price tag, right?
Interesting video regarding helmet design....But Mr Hil there needs to dump that stupid baseball cap....Come on man act your age....just sayin.
He must be going bald under there
Well, maybe he just wanted to have 'Bell' visible at all times, a he'd of looked really stupid wearing a helmet :p
buel no bell, they were an american motorcycle company
!
That guy looked like a 4 year old wearing his fathers hat.
As I can see in the sponsor list, either you or KASK recently quit the sponsorship ^^
Hey Gravity, we still wear Kask lids every day, the partnership is alive and well.
are all road bike helmets created equal in terms in quality?
*****
no, i meant $20 helmet vs $40 helmet vs $60 helmet. why is one selling it for $20/$40/$60. quality? markup? both? how do you tell if this one helmet is 20x better than that helmet?
*****
thanks sir!
How do I make my trucker hat so flat?
That Bell helmet makes you look like a Bell end...
Mushroom
Starwars Lego 2:18
Hil has as much personality as a hot dog bun.
Si should start lifting weights now as he is retired.