In winter sports innovation, finding a balance between safety and sustainability is often a challenge. However, Salomon has bridged this gap with the Brigade INDEX, the first fully recyclable ski helmet.
To understand the journey behind this revolutionary helmet, we spoke with Nans Girodengo from Salomon’s Innovation team. Nans shared insights into the meticulous process that led to the helmet’s creation and the circularity principles that guided its development.
From concept to reality: How it all began
In 2019, Salomon’s winter sports team embarked on a mission to improve the environmental impact of its products. The team realized that expanded polystyrene (EPS), a material commonly used in ski helmet cores, was a major environmental concern. Seeing the need for change, the team was inspired to explore innovative alternatives that could offer the same level of protection without compromising the environment.
Instead of using recycled materials as a temporary solution, the team aimed higher: they wanted to create a helmet that could be completely recycled at the end of its life.
“Ski and snowboard helmets are very complex to recycle because they combine many different materials. Without a way to separate these materials at the end of the helmet’s life, they often end up in landfills or are incinerated,” Nans says.
Selecting the right materials was a crucial part of developing the Brigade INDEX. “We needed to find a way to use the same material for all helmet parts to simplify the recycling process,” says Nans.
Initially lacking knowledge in designing recyclable products, the team partnered with Paprec, a French recycling company. This collaboration offered valuable insights into the challenges and requirements for creating a truly recyclable helmet. The teams exchanged ideas and prototypes, constantly assessing whether the proposed materials and designs could be effectively recycled.
“We searched for a material family that could be used for the entire helmet and finally settled on polypropylene (PP), a thermoplastic that can be heated and shaped in various forms,” Nans notes.
The use of a single material allows the Brigade INDEX helmet to be recycled at the end of its life without any disassembly. The helmet is composed of 96% polyolefins, including PP, which is widely used in other industries and enhances the efficiency of the recycling process.
A glimpse into Salomon’s design process:
Pioneering change: overcoming challenges and achieving success
For four years, the team pursued the ambitious goal of creating the first truly recyclable ski helmet. They saw the development of recyclable products not only as innovative, but also essential, giving them a strong sense of purpose. Initial skepticism about the project’s feasibility only motivated the team to prove that their concept was achievable.
“One of the most rewarding moments was our second visit to our recycling partner,” recalls Nans.
“They initially provided us with the ‘recipe’ for making a recyclable helmet: only use materials from the polypropylene family to avoid the need to separate different plastics later. When we returned with our first prototype, they were impressed by our commitment to sticking to the recipe. We didn’t cut corners or substitute difficult materials with easier alternatives. Their positive feedback was a major highlight for us.”
Redesigning the absorbent core of the helmet was a significant challenge, as using just polypropylene was uncommon in the industry, making it difficult to find reliable suppliers. Once suitable suppliers were found, the team had to ensure that the materials were pure polypropylene, which required rigorous testing and certification to meet safety standards.
“This intense learning period required us to adapt quickly to ensure our helmet could pass all impact tests without being on the borderline. Working with an external laboratory for testing and certification was invaluable,” Nans explains.
The team went through numerous design and prototyping iterations, rigorously testing each version to ensure maximum protection. They experimented with ten different helmet constructions, using various types and shapes of polypropylene and different injection techniques.
“We initially expected the outer shell and inner core, which are critical for protection and shock absorption, to be the most challenging to create. Through extensive testing, we learned that polypropylene offers excellent durability and resistance to scratches, along with great shock absorption when expanded,” says Nans.
“We even sent Brigade INDEX helmets to ski schools, known for heavy gear use, and received feedback, which confirms we succeeded in reaching our quality standards.”
Helmet’s journey beyond the slopes
The Brigade INDEX helmet reduces overall environmental impact by 19% compared to traditional counterparts. This significant reduction is largely due to the use of polyolefins, which require less energy to produce than other thermoplastics, and the helmet’s recyclability at the end of its life.
Salomon estimates that the helmet can last for five years with regular use, approximately 10 days per year, similar to other helmets in the range.
Feedback on the product has been very positive. Users appreciate that the product retains the same design and fit as the non-recyclable Brigade helmet.
“Achieving the same level of comfort and style with recyclable materials was challenging, but the end result is both beautiful and comfortable,” says Nans.
When the helmet is done protecting the skier’s head, they can be returned to Salomon free of charge. Salomon’s recycling partner Paprec will recycle the helmet entirely, transforming the reprocessed material into new products such as flowerpots, car bumpers, and crates—the possibilities for giving the helmet a new life beyond the slopes are endless.
What’s next?
Salomon is exploring ways to apply the same “recipe” used for the Brigade INDEX helmet to other products. While challenging, the team is committed to finding solutions.
“Research and consumer studies indicate that today’s consumers seek larger-scale sustainable solutions rather than small, limited initiatives,” says Nans.
Salomon aims to apply its recycling approach to a broader range of products, significantly reducing environmental impact and demonstrating its commitment to sustainable innovation.
Watch the video about the Brigade INDEX helmet on salomon.com.
