While interning at Giro Sport Design in summer 2019, my primary role was designing injection molded plastic parts for bicycle helmets. I created the parts using surfacing tools in Solidworks and added draft to ensure injection molded manufacturability.

Shown in photos is one part I designed, a hanger for attaching the chin strap to the EPS foam helmet shell. Previously Giro had to make three separate hangers for each of the three helmet sizes, but I designed this part so only one would be necessary, reducing tooling cost and BOM size. ABS plastic was used for this part because of its high strength and low cost.