THE
MAJOR

THE
MAJOR

THE
MAJOR

Bern Helmets

Bern’s style,
for more riders.

Bern’s style,
for more riders.

Bern’s style,
for more riders.


While Bern’s signature skate style has withstood the test of time, there was an ever-increasing gap in the market for a well-ventilated Bern helmet that could appeal to more riders. Bern had tons of existing data it wasn’t taking advantage of, so I introduced research into the design process to help define what should come next: the Major, a highly ventilated, MIPS-equipped helmet built around fit and comfort.

While Bern’s signature skate style has withstood the test of time, there was an ever-increasing gap in the market for a well-ventilated Bern helmet that could appeal to more riders. Bern had tons of existing data it wasn’t taking advantage of, so I introduced research into the design process to help define what should come next: the Major, a highly ventilated, MIPS-equipped helmet built around fit and comfort.

Digging In

Working with our Harvard Public Health & Safety co-op, we built an entirely new research process for Bern by combining customer data with research on how helmet-wearing behavior affects rider safety across demographics.

Insight 01

Price had a ceiling

While the brand appeals to a wide range of income levels, the largest growing audience had a limit to the amount they were willing to spend on a helmet — showing us the financial limits of what we could design.

Survey respondents by household income

Survey respondents by household income

$0–24k

$25–49k

$50–74k

$75–99k

$100–124k

$125–149k

$150–174k

$175–199k

insight 02

One helmet, many riders

Riders use the same helmet across activities, so we knew we had to reach as many rides as possible.

01 / Bike

Road
Mountain

Road
Mountain

02 / Wheels

Skate
Inline

Skate
Inline

03 / Snow

Snowboard
Ski

Snowboard
Ski

insight 03

Customer priorities, in order

We assumed safety was the primary reason customers chose a helmet. Our research challenged that assumption: fit and comfort were the strongest purchase motivators, ranking above both style and safety.

  1. Fit

  2. Comfort

  3. Style

  4. Safety standards

  5. Color

insight 04

Underserved climates

High ventilation became non-negotiable for a company wanting to grow their market to warmer states.

Heat map showing the opportunity in warm climates

With the design direction established, I developed the helmet in SolidWorks and produced full-scale prototypes on a Z18. I integrated the dial-fit system, MIPS low-friction layer, and padding to evaluate fit and comfort with a diverse group of riders.

With the design direction established, I developed the helmet in SolidWorks and produced full-scale prototypes on a Z18. I integrated the dial-fit system, MIPS low-friction layer, and padding to evaluate fit and comfort with a diverse group of riders.

Tried and tested.

Tried and tested.

Tried and tested.

Tried and tested.

The Major launched as Bern’s most ventilated commuter helmet and sold well. It earned a 5-star rating from the Virginia Tech Helmet Lab, their highest score for reducing concussion risk.The research held up in the real world. Reviewers praised the airflow, light weight, and comfort.

The Major launched as Bern’s most ventilated commuter helmet and sold well. It earned a 5-star rating from the Virginia Tech Helmet Lab, their highest score for reducing concussion risk.The research held up in the real world. Reviewers praised the airflow, light weight, and comfort.

The Major launched as Bern’s most ventilated commuter helmet and sold well. It earned a 5-star rating from the Virginia Tech Helmet Lab, their highest score for reducing concussion risk.The research held up in the real world. Reviewers praised the airflow, light weight, and comfort.

— Sam Kilburn, Outdoor Prolink

“It was love at first sight with the Bern Major”

“It was love at first sight with the Bern Major”

“It was love at first sight with the Bern Major”

— Sam Kilburn, Outdoor Prolink

BUILT FOR HOWEVER YOU MOVE.

BUILT FOR HOWEVER YOU MOVE.

Next project

WONDERLAND

REI