INSIDE RAZOR: MIPS HQ report - Video

FOR SURE, YOU KNOW THIS YELLOW HELMET INSERTION CALLED MIPS, RIGHT? HAVE YOU EVER WONDER HOW IT IS DEVELOPED, TESTED AND PRODUCED? WE KNOW THAT, BECAUSE WE VISIT MIPS HEADQUARTER IN STOKHOLM, SWEDEN! CHECK OUT OUR SHORT REPORT!


We were very excited about this visit ever since we receive an invitation to new MIPS headquarters in Stokholm. We heard a lot about safety advantages of MIPS but we never had an opportunity to see the development and testing processes made on MIPS for every helmet individually.


C-shaped building with wonderful Scandinavian-style offices, testing facility and wonderful coffee corner - the new MIPS HQ is a really nice place to work. People are smiling and willing to talk – like a family. Everyone knows everybody in the company. They’re passionate and know their mission - to make sports safer and more pleasant. They are not only into biking, but also into motorsports, horse racing, skiing and other disciplines which require wearing a helmet. Back to the helmet itself...



The beginning...
As you already know from our first article that Kellys Razor helmet is available with MIPS system, which protects your brain from excessive strains during heavy impact. LFL (Low Friction Layer) placed between helmet shell and lining can move relatively to the helmet’s shell which reduces strains inside the skull. Looks pretty simple, works really simple, but creating LFL for the helmet is a time consuming and complicated job.
LFL is created individually for each of helmet models and sizes! Before MIPS' guys decided of making LFL for Razor, our helmet had to pass demanding tests and met MIPS standards which determine the possibility to create LFL for the helmet. Only modern, quality-made helmets with high build-in safety are appropriate to work with in MIPS.



Razor, as an enduro helmet made with in-mold technology with extended rear part and increased shell depth passed first tests perfectly. In MIPS’ testing facility the technicians tested also Razor prototypes to ensure that our R&D department is going right way with new helmet project. After many tests, many simulated falls MIPS engineers started to work on the first in history LFL for Kellys helmet.

First thing to do is to create a 3-D model of LFL on an computer. Shape of this yellow layer is based not only on the shape of the shell, but also on air vents location, lining elements and type of size adjustment system. When the project is ready it is time to make a first LFL prototype. Removed from the helmet it looks like yellow cup made of some plastic. Do not be fooled! LFL is made of special synthetic material and preformed before cut to its final shape by CNC machines! Really precise work. There is no other way. Individual LFL for every helmet’s size is prepared and then fitted into shell by elastic elements allows LFL to move inside.



Time to test.
In the MIPS HQ basement there is a large testing facility equipped with modern gear and tools. The most important machines simulate different types of impacts. With crash-test dummy’s head (Yep! The same as used in cars’ crash-tests!) MIPS’ engineers check helmet in virtually every possible way. Static fall, rotational fall, frontal impact, both side impact, with or without visor and many others. Except these quite big machines, there is a lot of high speed cameras, computers and dozens of g-sensors placed inside of dummy's head. According to the readings engineers determine the difference in strains level between MIPS and non-MIPS helmet. Believe us – they are really significant. Moreover, results show that helmet already damaged by impact loses some of its protection capabilities, especially without LFL. It’s good to know, especially if you want to wear your helmet after heavy fall.


Final product.
Next step is to find another improvements, to increase results to the highest possible level. It requires LFL further modifications and improvements. When the day has come and MIPS’ R&D department provides the best possible LFL for the Razor it’s time to introduce it to the mass production. CNC program is written to make LFLs in the factory. Yes! Not only the prototype is made by precise CNC cutters!
Whole process can take more than year from early projects to its final form and production. It was a great day to us, when we can hung our Razor on MIPS’ wall-of-fame.


Stay tuned for other news about Razor!

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MENTIONS: @KellysBicycles / @MIPS

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