The WaveCel helmet program was a major design and engineering effort at Trek Bicycles, led by a team including Robert Perri, Colin Hansel, Ivan Luccion, and a world-class helmet engineering group. The work effectively combined three parallel efforts into one program: integrating new WaveCel safety technology, delivering across multiple products, and meeting an aggressive launch schedule. I served as design manager and contributing designer, helping bring the technology to market and drive a significant commercial impact upon launch. All rendered imagery shown here created by me.
Trek Circuit Wavecel: Designed in 2016 and still going in 2026. Renderings by me, industrial design concept work by Ivan Luccion. Production work by Robert Perri, and myself.
The Charge Wavecel helmet was introduced in 2018. I did the production industrial design along with modeler Robert Perri.
I was fortunate to work with Robert Perri ho was the lead model maker for all of Bontrager's helmets. I learned the process from him, which is very hands-on and very iterative.
The Wavecel XXX is an evolution of the Ballista that was a groundbreaking helmet from the Bontrager team.
We evolved the design further and incorporated Wavecel technology to create a helmet just as fast, but now safer than ever.
We evolved the design further and incorporated Wavecel technology to create a helmet just as fast, but now safer than ever.
Velocis 3.0 Helmet (2022 - Images Below)
The original industrial design intent was created by Colin Hansel. Following his departure—and my return to Trek—I was tasked with carrying the program through to production. Starting from Colin’s Rhino model, I rebuilt the helmet in SolidWorks and worked directly with engineer Jesse Garrison to prepare the Velocis for testing and manufacture. Renderings by me.
The original industrial design intent was created by Colin Hansel. Following his departure—and my return to Trek—I was tasked with carrying the program through to production. Starting from Colin’s Rhino model, I rebuilt the helmet in SolidWorks and worked directly with engineer Jesse Garrison to prepare the Velocis for testing and manufacture. Renderings by me.
Comparison of Colin's original Rhino model to the production design from Jesse and I.
I was a month back into Trek and we had to re-work some of the Velocis structural elements
Rethinking the carbon cage and doing rough prototyping...it gets messy
Most of the concept work was done, still some sketching needed
An early 3D print, making updates
Helmet design is challenging.: A perfect balance of weight, aerodynamics, strength, and fashion
