Safety Helmet

Pushing the boundaries on comfort
In short
An intense collaboration to produce one of the top rated Type 2 Safety Helmets in the industry
What we did

Industrial Design

Design for Manufacture

Prototyping and Production

Defender Safety
Finished on
February 2023
No items found.
Safety Helmet

13 total parts in the assembly

Each component was carefully designed and chosen to optimize safety, comfort, durability, cost, and of course, style. All parts match standards in the field and also include innovation in key areas.

An intense collaboration to produce one of the top rated Type 2 Safety Helmets in the industry

Safety Standards

The helmet comes in class C and E.

One catering for optimum comfort with increased ventilation and the other with no vents for situations where electrical insulation is paramount.

The helmet passed ANSI z89.1

Both helmets protect impact from top and sides and the Class E protects up to 20 000 volts.

Multiple patented features were filed on the helmet design.


The H2 was designed from the ground up for maximum comfort.

Breathability has been a key benefit in the sales of the Safety Helmet.

Open vents on the outside feed into airflow channels in the internal EPS. The headliner allows airflow to flow through and provides comfort and support.

Conceptual Design

is one of the most important and visually inspiring aspects in developing a product. We worked through multiple styles and features to find the perfect Defender Safety aesthetic.

Five working prototypes were made during the design phase to ensure all the details were tested and signed off before going into production.

Nylon sintered prototypes provide a very good analysis of plastic parts designed for injection moulding.

Prototyping was a vital part insuring perfect fitment for the helmet

Full production of both the classes started in March 2023 with ANSI and EN testing passed successfully.

After 10 months of design and 8 months of production and testing, the helmet hit the market in 2023.

Selected work

With you every step of the process

We believe in building products that make sense for the real world.

"We have developed more than 10 products with DMC. The team have incredible technical skills and are so easy to work with. They know how to listen, track our meetings, and give us clear project timelines."


Plan properly and set up a strong foundation for your product’s development. Research and initial concept exploration goes a long way in ensuring your product idea is viable.

Ideation and Design

Figure out the function, explore the aesthetics and choose a basic conceptual direction to create solution for your business. Expect sketching, CAD and prototyping in this phase.

Engineering Design

Turn that concept design into a fully functional physical prototype that can be manufactured. It's imperative we test our assumptions in the real world and make sure your design can be manufactured!


Finally, your idea is validated, the product can be mass manufactured, and you're now ready to set up your manufacture partners and begin selling your idea to the world.

Get in touch

Every project is unique and requires it's own plan. Get in touch so we can listen to your needs and draft a plan to build an epic solution.

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