My process began with extensive market research, analyzing existing cycling helmets and identifying key trends in materials, features, and user needs. This research informed the strategic direction for the Under Armour sub-line, "UA Velocity," designed to resonate with the extreme sports audience. I focused on understanding what motivates extreme cyclists – the thrill of the ride, the pursuit of peak performance, and the need for reliable protection.

The initial design phase for the helmet centered on a deep exploration of sustainable alternatives to traditional cellular foam. Driven by a commitment to environmental responsibility, I investigated materials like mycelium foam insulation, developing various prototypes to assess its viability. While promising in its eco-friendly nature, the challenges of achieving consistent sophisticated aesthetics and scalable replication led to a strategic pivot. Recognizing the burgeoning success of 3D-printed cycling saddles and the potential for intricate, organic cellular structures, the project shifted focus towards additive manufacturing. This transition opened up exciting possibilities for material exploration, allowing us to leverage advanced polymers and create complex internal geometries. The goal became to engineer the ultimate lightweight yet exceptionally safe helmet in the industry, utilizing the precision and customization offered by 3D printing to optimize impact absorption and ventilation through carefully designed cellular patterns.