Designed for the demands of modern downhill; tracer.pcs integrates Avient’s polystrand composite shell with a magnetic-release visor and spherical impact liner, creating a lightweight, high-strength system optimized for cooling and comfort.
August - October 2025
Software: Rhino, Sketchbook, Keyshot, Photoshop, Illustrator
Polystrand is a continuous glass-reinforced thermoplastic polypropylene composite material.
Impact Resistant
Lightweight
Available in different ply thicknesses
Compression moldable up to 3in draw
Polystrand's ability to be compression molded enables quicker manufacturing, making it a good middle ground material for a helmet's outer shell.
Starting in Sketchbook, I rattled out a rough form, then moved into Illustrator to find a final concept.
Since Polystrand is unable to stretch past a draw depth of 3 inches, the helmet's outer shell is constructed with 9 panels that assemble onto an EPS foam liner.
I started with an AI generated model made with Vizcom, and used it as an underlay to block out my primary surfaces in Rhino.
Small bristol paper models helped figure out the 3D form of the visor.
Once the outer surface shell was complete, I used Keyshot to check surface quality and proportions. I decided to make a few changes, like shortening the chinbar, and increasing fillet radii.
Fit Testing
The first full scale prototype was too narrow to fit a head in, so adjustments had to be made.
Using CageEdit in Rhino, I was able to modify the fit and proportions of the helmet based on findings from the first prototype. The second full scale model was more successful, fitting nicely and integrating well with goggles and action cameras.
2025 © Carter Lindblom