Aeon Helmet front side view
Aeon Helmet rear view
Proto-type tooling cad for a helmet we molded to learn about the proposed design. While not used for production, this exercise was invaluable in the assessment of proper beam thickness and orientation. Cad done by me.
Early concept art showing the submerged inner polycarbonate cap. This would give Aeon its primary structural support and iconic look.
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Aeon Helmet

Pre-2010: In the battle for the lightest high end road helmet on the market Giro was coming in 2nd or 3rd. That was challenged by the Aeon but it was the Giro Prolight which became lightest.

Industrial Design: Greg Marting. Greg's design was altered only slightly by me, in the orientation of some of the cross beams for structural integrity.

My role as mechanical lead: the EPS foam submerged "Inner Cage" as marketing called it, was the first reinforcement of it's kind. I invented this without a patent and found it to be copied by many brands in years afterwards. As its predecessors were the Atmos and the Ionos, both helmets employing carbon fiber thermoplastics in their reinforcement systems, it was a tough sell to remove all carbon and just use polycarbonate shells instead. Worked with the vendor development team and Bell's Far East Team to accomplish manufacturing readiness and testing. This was my third helmet as ME lead for Giro and I was honored to assist Greg.

Gregg Jacobsen
Sr. Mechanical Design Engineer Santa Cruz, CA