Collaboration Efficient development and design—even with global teams

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To make motorcycle and mountain bike rides safer, O'Neal, in collaboration with Quintessential Design, developed a smart helmet. They mastered the challenge of managing the development process with multiple parties using a shared digital platform—and reduced the development time by fourfold.

When thinking about motorcycle or mountain bike excursions, freedom, mud, gravel, tight curves, and endless roads probably come to mind first: pure adventure. However, both sports pose risks that should not be underestimated. To avoid serious injuries, the market today offers a range of sophisticated technical equipment. A new addition includes a helmet from the Baden-Württemberg manufacturer O'Neal and the American company Quintessential Design.

The helmet is equipped with an integrated sensor that fits modularly into the base of the helmet and connects to an app on the rider's mobile phone. This gadget can detect an impact and ensure that the rider receives the necessary help as quickly as possible after an accident—even if they are unable to call for help themselves.

Increased Safety: Sensor Detects Impacts

Both companies were driven by personal experiences that showed the severe consequences of accidents during mountain biking and motorcycle tours—especially when riders were not medically attended to in a timely manner. Against this backdrop, both companies aimed to develop solutions that ensure greater safety for mountain bikers and motorcyclists. O'Neal, a manufacturer of protective clothing and accessories, focused on physical safety through sophisticated helmet design. Quintessential Design, an IT and electronics system developer, created technology for sensors that detect impacts and for GPS tracking.

Quintessential Design's sensor is currently the only system in the world that captures and aggregates gyroscope data, magnetometer data, and acceleration data in compliance with data protection regulations. Using these data, a specially programmed algorithm determines whether a helmet hits the ground, the force and speed of the impact, and the angle of impact— all crucial information for enhancing the safety of the rider.

Global Teams, Multiple Trades: Agile Development with Digital Tools

The special challenge lay not only in developing a design that is modular for all six different helmet models from O'Neal but also in coordinating the project: Both companies work in teams distributed across the globe. Coordinating the distribution and execution of tasks across multiple locations can quickly become complex and time-consuming.

The challenges of working across different time zones and the fragmented nature of tasks when different teams work on various parts of a product often lead to increased administrative effort. Issues such as quality control, integration of work results, and comprehensive testing can be more difficult with distributed teams. Especially, distributed teams need to be flexible and quickly adaptable to changes. The solution for Quintessential Design and O’Neal lay in the implementation of agile methodologies and the joint use of suitable digital tools. This approach allowed for better synchronization of tasks, improved communication, and more efficient problem-solving, ensuring continuity and consistency throughout the project. Agile practices, such as regular stand-ups, sprints, and retrospectives, also helped to maintain a clear focus and foster a collaborative environment despite the geographical dispersion of their teams.

From Concept to Helmet: Effortless Design Process Thanks to Digital Software

Autodesk Fusion was chosen as the digital tool for developing the helmet. Both companies had previous experience with the solution. This allowed the teams to efficiently represent all necessary steps of product development within one solution and to work together on a design without significant delays.

Autodesk Fusion combines CAD, CAM, and CAE functions in an integrated cloud software platform. It includes all the tools needed to seamlessly execute all processes from design to manufacturing.

The entire preliminary development was handled via the software, including across different trades. Relevant files were exchanged directly in the same file format, and necessary changes and adjustments could be made quickly. This led to a fourfold reduction in development time.

Only after all design decisions were made and the helmet model was finalized, were the files sent to the manufacturing companies, primarily located in Asia. This seamless transmission allowed Quintessential Design and O'Neal to move from concept to finished helmet in record time. This case highlights how companies like O'Neal and Quintessential Design streamline their processes using digital tools—a strategy confirmed by 60 percent of the executives, researchers, and professionals from architecture, engineering, construction, product development, manufacturing, as well as media and entertainment surveyed for the State of Design and Make Report 2024 by Autodesk. This approach not only enhances efficiency but also improves accuracy and speed in bringing new products to market.

This case illustrates how companies like O'Neal and Quintessential Design streamline their processes using digital tools—a strategy that is confirmed by 60 percent of the executives, researchers, and professionals from architecture, engineering, construction, product development, manufacturing, as well as media and entertainment who were surveyed for the State of Design and Make Report 2024 by Autodesk. This widespread adoption underscores the critical role digital technologies play in improving efficiency, reducing time to market, and enhancing collaboration across diverse geographical locations.

More Than Just Design: 
Keeping the Entire Lifecycle in View

In addition to streamlined processes and efficient communication, working with a shared digital model brought further benefits, as reported by Anirudha Surabhi, CEO and founder of Quintessential Design. Utilizing tools available through Fusion allowed the entire lifecycle of the product to be examined. Thus, the partners also gained insights into the prerequisites for the helmets' recyclability and could incorporate sustainability considerations into their design from the early stages. This enabled them to adopt a holistic view of their product and factor in all aspects that were particularly important to them. This approach not only enhances product design from an environmental perspective but also aligns with increasing consumer and regulatory demands for sustainable products.

For O'Neal, alongside the safety aspects brought by the integration of Quin's device, the future-proof nature of the solution also played a crucial role. Ride Analytics, supported by Artificial Intelligence, and gamification are becoming increasingly popular and will play a significant role in the future motor and mountain bike market. By engaging in this partnership, O'Neal is investing in its future, creating opportunities to flexibly adapt its offerings. Thanks to a modular system, the technology can potentially be implemented in all O'Neal helmets, allowing the company to stay ahead in the market by integrating cutting-edge technology that aligns with emerging consumer trends and technological advancements.