Sail Helmet
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A sculpted sailing helmet specialized for the high-risk sailing performance of SailGP athletes.

Duration 3 weeks — 2024
Skills Deep Research · SolidWorks · Keyshot · Vizcom
Category Safety Equipment · Sports Performance · System Design
SailGP Emirates
SailGP racing
SailGP crew
SailGP foiling
SailGP action

Context

SailGP is the most advanced sailing fleet racing series in the world. Boats travel over 3× faster than the wind — up to 104 km/h — and mark-rounding speeds expose sailors to up to 3Gs of g-force.

The all-carbon F50 catamarans use hydrofoils to fly above the water, making them some of the most maneuverable and volatile boats on the planet.

SailGP is the Formula 1 of sailing.

SailGP boats are at the cutting edge of sailing technology — yet the athlete safety systems haven't evolved at the same pace.

Hans Henken — U.S. SailGP Team

Hans Henken

Age 26

  • U.S. SailGP Team — Grinder
  • Olympic bronze medalist, 49er class (Paris 2024)
  • Member of the U.S. Sailing Team
  • Specializes in high-performance skiff sailing and strength-intensive roles onboard

Hans is known for his athletic power, calm competitiveness, and analytical approach to performance. Off the water, he brings a systems-minded perspective to training, teamwork, and gear — focused on marginal gains and long-term development.

Hans worked with me throughout the design process, providing key insights into the sport's demands and where current safety gear falls short.

The head becomes the convergence point of protection, communication, and visibility.

Primary Research Partner

Problem Statement

SailGP sailors need a purpose-designed helmet system that integrates protection, communication, and visibility while enabling athlete-specific fit and circular design strategies.

Constraints, Considerations & Parameters

Function

  • Protects athlete in crash & capsize
  • Doesn't interfere with sailing performance
  • Enables athlete communication
  • Easy access to regulator

User Experience

  • Comfortable for extended wear
  • Easy to put on and take off
  • Visually appealing
  • Hypes athlete up to wear it
  • Lightweight

Weather

  • Ventilation in heat
  • Sun protection
  • Doesn't absorb or hold water
  • Easy drainage after capsize
  • Waterproof
  • Doesn't corrode in salt water

Sustainability

  • Reduce number of material types
  • Design for disassembly
  • Easy to repair
  • Sustainable & recyclable materials
  • Reduce total material volume

Anatomy Of A Helmet

Helmet Exploded View
Nautilus Moodboard
Fast Dynamic Performance Sublime High Tech Organic Focused Precise
Ideation 1 Sketch Spec 3 Ideation 3 Ideation 2 Spec 2
Concept A Concept D Concept C Concept B
Scale Model 1 Scale Model 2 Scale Model 3 Scale Model 4

Nautilus Helmet System

Nautilus render 3 Nautilus render 1 Nautilus render 2
Nautilus in context 1 Nautilus in context 2

Learning
Takeaways

01

Deep research before any form work is non-negotiable for safety equipment — without understanding crash dynamics and injury patterns, early form decisions would have been structurally hollow.

02

Complex products require designing relationships between subsystems, not just the subsystems themselves. Coordinating protection, communication, fit, and service revealed that decisions in one area consistently impacted others. Mapping these relationships became essential to maintaining a cohesive system rather than a collection of parts.

03

Speaking with Hans Henken surfaced gaps that weren't visible through secondary research alone, particularly around communication and long-duration comfort. These insights redirected the project toward integration and usability, rather than purely performance-driven assumptions.

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