This thesis project aims at exploring the challenges of sustainability within the segment of ski-helmets. It should lead to locating opportunities for transitioning them into the Circular Economy.

Ski-helmets are single-impact items, comprised of multiple different materials in inseparable product assemblies that prevent disassembly and recyclability. They are discarded after critical impacts, when safety critical parts fail. This also happens, when product parts with crucial perceived value deteriorate visually or fail to fit current fashion trends. Facilitating repair or refurbishment is currently obstructed through certifications and future developments seem promising but unsure. After discarding, helmets are not recycled, which leads to the loss of resources, energy and value.
Different ski-helmets were analysed on their ease of disassembly and their environmental impact using tools like HotSpot-Mapping, Disassembly Maps and Life Cycle Assessment. A survey and interviews were conducted for gaining insights into user-behaviour and expertise in ski-helmets and beyond.

The project’s outcome is a visionary concept for transitioning ski-helmets into the Circular Economy — the Airguard concept. The proposal includes a novel approach on energy-management, rather than using single-impact EPS-foam. A system of TPU air-vessels enables the absorption of multiple impacts and the structure can be easily restored through remanufacturing.

The Airguard concept is developed to fit into processes like recycling and remanufacturing. It is integrated into an assembly base with less different materials used, enabling product disassembly and improved access to parts with high impact, embedded energy and economic value — The priority parts.

The assembly base includes the possibility to change parts which subject to deterioration, like visors and soft-liners. Additionally, it provides a modular base for product add-ons and upgrades, increasing usability, flexibility and longevity.
After the product’s end of use, an incentive take-back system should enable retrieving used products to regain their value through recycling and remanufacturing.
As an intermediate step, the Eco-Savor concept was developed, focusing on recycling, while using the same assembly base as the Airguard concept, built around a core of trusted EPS. As a stepping stone, it should be used to improve product architecture and for gathering insights on part durability for later remanufacturing. A roadmap was developed to indicate development steps over the timeline of six years.

In the end, both concepts should stand as a vision towards sustainability, with many features to further explore and the possibility to gradually decrease environmental impact in ski-helmets.