Impossibile! Part 02:From Caravaggio with Love.

Caravaggio, Northern Italy. A Friday in November. Fog sits low over the Po Plain, thick enough to swallow the horizon. Somewhere beyond it are the Alps, but not today — today there is nothing but grey, pressing down flat and close over the flatland. The workshop is draughty, the kind of cold that gets into your knuckles. Only the workshop manager's office has heat, and everyone who passes finds a reason to linger by the door a little longer than necessary. We were supposed to have left Bergamo by now. But the last details are never really the last details, and we're on our third espresso, waiting. FELICE IS STILL AT WORK, MOMENTO.. He is the wizard of this place. A legend among shapers, the man who once cut leather caps for Brancale and has quietly shaped a good part of Italy's finest helmets for decades. As far as we know, he's the only toolmaker left who can carve the two perfectly symmetrical halves of a three-part helmet mould by hand — no copy mill, no mirror function in CAD. Just eye, blade, and instinct. ABUS and Tom Ayton have worked alongside Felice since the very first Gamechanger, and we're still learning from him. With a lot of respect. He's the hands-on one — nobody touches foam like Felice does. We're the opposite breed: virtual wind tunnels, 3D printing, an "all-in-Rhino" way of thinking that replaced our physical prototype shop a decade ago. If it's not in the data, as far as we're concerned, it hasn't happened yet. And yet none of the aluminium tooling, none of the Necuron blocks, would mean anything without Felice's hands. Without the way his accent slides from Italian into Bergamasque the moment something gets emotional. AND WITH HELMETS; EVERYTHING IS EMOTIONAL. TRUST HIM ON THAT. Airbreaker 02 is on its way to tooling now. The data is locked, the wind-tunnel numbers are in, and we've already ridden a 3D-printed prototype through the hills. It gave us exactly what we hoped for: better airflow across the forehead. Same weight target. Same fit. Same FlowStraps. Everything a successor to a bestseller should carry forward. Almost everything. The sunglasses integration still needs one more pass — nothing can rattle, not even after a few thousand kilometres in the saddle.  Because this helmet is headed for the pros next. And that changes the whole equation. A professional team doesn't care how clever a solution looked in a slide deck. They care whether it holds at 60 km/h, in the rain, mid-bunch, on the final climb of a Grand Tour. So we keep looking. We keep adjusting. THREE-DIMENSIONAL CHESS Visually, Airbreaker 02 is not a revolution — and that's exactly the point. The brief was never to make it look different. It was to make it work better. American safety-standard compatibility had to be folded in without touching the ventilation that made the original a hit in the first place. Seven ventilation channels had to run uninterrupted through a shell whose every angle, transition, and deformation curve leaves almost no margin for compromise. Inside out, every millimetre of foam has a job to do. Every angle has a consequence somewhere else. It's less like designing a shell and more like playing three-dimensional chess — where moving one piece changes the whole board. And that's where the real successor gets made. Not in the render, not in the pitch. In the mould. In the prototype. In the wind tunnel and on the open road. And eventually — in the peloton. And who knows — maybe one day Enric Mas crosses the finish line of the La Vuelta wearing a fire bright red one. For now, that's still just a nice thought to hold onto. Airbreaker 02.From Caravaggio with Love.

Client

ABUS August Bremicker und Söhne

Year

Project start: 2021Release: 2022

Services

Ergonomic DefinitionPerformance ResearchDesign & ModellingEngineeringDesign StrategyAdditive Manufacturing

Awards

Eurobike AwardRedDot Award

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