Bell Falcon XR Gravel Helmet
Bell Falcon XR rear view showing blinky light.
Falcon XR on a rider
Showing CAD of visor version of the Falcon XR.
Inside view Falcon XR. This helmet has a plastic injection molded MIPS low friction layer.
Falcon XR CAD, rear side view.
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Bell Falcon XR Helmet

This 2022 Bell helmet is the mid-price-point model in Bell's Gravel category.
Industrial Designer Franco Boffi

My role was fairly heavy on this one. Franco preferred that I take over surfacing CAD early on, updating iteratively with him through final design phases. My designed components: rear plastic reinforcement, front plastic reinforcement, MIPS low friction layer, fit system height adjustor, all other components are co-designed with Franco.

Mid-project Marketing wanted a mountable Blinky light. This impacted the schedule, of course, but not by much. We delayed tooling release while I designed the light and means to mount with support of the rear plastic reinforcement. Franco directed the external cosmetics.

Gregg Jacobsen
Sr. Mechanical Design Engineer Santa Cruz, CA