The challenge
Since helmets became mandatory, the cap moved under the shell — and most factories got it wrong. Too thick and the helmet sits high and unsafe; too slick and sweat stings the eyes at 40 km/h. The brand needed a cap that adds comfort without changing helmet fit, across 5 helmet brands their team actually rides.
Our solution
Co-developed an ultra-thin micro-mesh with flat-locked seams and a short curved brim engineered to clear helmet straps. Fit-tested under 5 helmet brands with the brand's race team, added reflective prints that stay visible after 50 washes.
Results
30,000
Pieces per season
50
Wash cycles, reflective intact
5
Helmet brands fit-tested
2
Season contracts renewed
"They argued with us about millimetres. That's exactly why we stayed."
Products we made
- Cycling caps
- Reflective prints
- Moisture-wicking 4-panels
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