Abus Gamechanger 2.0 - Made in Italy
10.07.23 09:09 1012023-07-10T09:09:00+02:00Text: Erwin Haiden (translated by AI)Photos: Davide Arduini, Erwin Haiden, Abus (Presse)Join us on a journey to the cycling-affine Bassano del Grappa, where not far from the Giro d'Italia route, not only the wine but also the highly technical and specialized production of new Abus helmets has been flourishing for some years now.10.07.23 09:09 1232023-07-10T09:09:00+02:00Abus Gamechanger 2.0 - Made in Italy
10.07.23 09:09 1232023-07-10T09:09:00+02:00 Erwin Haiden (translated by AI) Davide Arduini, Erwin Haiden, Abus (Presse)Join us on a journey to the cycling-affine Bassano del Grappa, where not far from the Giro d'Italia route, not only the wine but also the highly technical and specialized production of new Abus helmets has been flourishing for some years now.10.07.23 09:09 1232023-07-10T09:09:00+02:00
Made in Italy - what lies behind these three words, why helmet production in Europe is a big deal, and why the name "Gamechanger" is programmatic, that's what I want to share with you in this, my, insider reportage.
For me, as a cyclist and technician, it is always something special to be shown the sacred halls of manufacturing, the well-guarded secrets of product development by the very people who are directly, closely, and almost daily involved with it. It becomes even more exciting when a bit of history joins in over a glass of Grappa, a glimpse into the future unfolds over the finest Italian espresso, and the grand finale is a nice road bike ride with the new product.
With that, we've outlined the main reasons why Abus invited a handful of journalists to the presentation of the new "Gamechanger 2.0" in Bassano. The name Gamechanger is both a program and an announcement at the same time.
For the successful security technology specialists from the southeastern Ruhr region, it was the start of a new era when they met the exceptionally experienced plastic producers Oliver and Massimo Simonaggio and their company in the year 2000.
After the first Gamechanger turned a vision into reality, it happened that after several more models, entering professional sports, and increasingly intensive successful collaboration, two years ago the first Italian producer, Maxi Studio, was integrated into the Abus group. And not only that. The plans for a new, larger, and even more modern helmet factory are now being implemented. The new factory is to be 4,000 square meters - with a lot of potential for expansion.
Why this is not only a big deal for Abus but for all parties involved is obvious. And to give you a better idea of what's behind a product as seemingly simple as a bicycle helmet at first glance, I need to start from the beginning and let the next few images of the design process and its details do the talking.
Entered the game and changed it forever
Gamechanger
Step 1: The Mission
As you can guess from these first photos, a modern high-end helmet is all about the tiniest details, which under certain circumstances can make a huge difference. The primary mission is clear: for a helmet like the Gamechanger, besides the logical safety aspect and wearing comfort, the best possible aerodynamics are especially important.
Aero is King
For a game-changing ride with Alessandro Ballan, even NoSane shaves his biker legs
It was important to the product developers at Abus to have a wind tunnel testing environment that was as realistic as possible. After all, aerodynamically "complex" areas such as the ears, glasses, and straps, as well as the angle of impact of the headwind play a decisive role. A fluttering helmet strap can negate the aerodynamic advantage of a helmet in no time at all.
And in contrast to all computational, mathematical ideals, there are practice-relevant issues such as wearing comfort, as the helmet should fit as many different head shapes as possible, be as lightweight as possible, of course without compromising safety, have the best possible ventilation, simple handling and adjustment; and in the end, the overall design should also look pretty sharp.
form follows function
CAD models, prototypes, numerous wind tunnel tests to analyze aerodynamics, and feedback from professional teams ultimately determine the appearance of the final product
Step 2: Design
This brings me directly to the next step. As you can see in the photos above, Hannes was kind enough to wear the helmet for a few photos in a worthy setup on the time trial bike.
I personally find it quite stylish. In fact, NoPain and I had our road helmets elaborately painted a few years ago. Since then, my Airbreaker has accompanied me on every road bike and gravel tour.
With the new Gamechanger 2.0, the changed opening at the forehead (Eyebrow-Vents) is immediately noticeable, which ensures even better airflow through the helmet. The channels in the helmet have been modified to maximize ventilation. The louver-like wings in the vertically ascending air openings provide good ventilation in the "race position," and as soon as you go into aero or sprint position, the aerodynamics improve drastically with less ventilation.
An exciting detail is also the straps, which are sewn with a special technique to prevent fluttering or even twisting in strong headwind.
The front of the new Airbreaker is shaped a bit more parabolically, with an unchanged overall length. The sides have been slightly raised to give more space to the glasses temple.
Another design feature is the Aeroblade. Here too, Abus tested numerous variants to arrive at the final shape.
The MIPS version is equipped with a Fidlock closure, the basic version with a Nexus closure. And both versions can be upgraded with the Abus crash sensor thanks to the Quin-Port.
Overall, the Gamechanger 2.0 is available in eleven (!) different colors.
Step 3: Colors and Shapes
And this multitude of colors, along with the additional requirements and special requests and designs from various teams, requires a high degree of flexibility in manufacturing. To ultimately create a safety-relevant, highly technical, yet individual product from the sheets in the lower photo and a bit of plastic granulate, it takes a lot of know-how and experience.
In the first run, the 0.75 mm thick plastic sheets are cut to the correct size, then printed with the corresponding design colors. Depending on the helmet design, there can be up to seven colors. The last layer of paint is a transparent adhesive that is essential for the subsequent EPS injection molding.
After printing, the outer shell is shaped. In the so-called thermoforming process, the plate is heated and the melting plastic is pulled over the tool at the same time. Process temperatures and times are a closely guarded secret for good reason. The plastic stretches, expands, and then shrinks again. In the end, everything has to fit with millimeter precision.
After the material has cooled down, the individual parts of the outer shell are partially separated by hand, but mostly using a CNC milling machine, to be packed at the end of the work step and taken to the next factory.
Step 4: Black Beads
The helmet in its final form is produced at an Abus facility elsewhere. There, near Treviso, they specialize in plastic packaging, insulation, and various other applications using the extrusion process.
Expanded polystyrene, or EPS for short, is the material that we all are familiar with, not only as the inner material of modern helmets.
Firmly walled in the earth stands the mold burnt from clay
In-Lehm: Traditional Casting Technique on a Large Scale - from Friedrich Schiller's "The Song of the Bell
The injection molding machines and tools from Abus are located in their own hall of the factory and stand out in their complexity at first glance from the crowd of steaming, hissing, cutting, folding, continuously moving machines. Even for the layman, it is immediately apparent that the metal mold, in which the machinists place the delivered parts of the helmet's outer shell, with all its recesses and openings, is an extremely complex work.
The black granules are the raw material for the inner shell. Vaporized with water, swelled in the exact right ratio (which is different for the American market than for the European) they must rest for a few days. The final fusion with the outer shell, the true magic, happens in the injection mold.
Prepared plastic beads, liquefied, injected into the mold with pressure, fused with the adhesive of the outer shell and the attachments, brought to expansion with hot steam, cooled down again with cold water, completed to come out of the mold
In-Mold: modern small-scale plastic injection molding techniqueIn the end, the outer shell and inner shell are one not only thanks to the adhesive layer. All features, mounts for straps and adjustments, air channels, and small details have now merged into one whole and, after a manual quality check, are returned to Maxi Studio to the department responsible for the final finishing touches.
Step 5: Details
Once again, the helmet moves into a machine. The prints such as various logos, the smallest details, and last but not least the Made-In-Italy inscription must be printed precisely, without distortion, and in the highest quality. Therefore, these fine details are applied using pad printing in the penultimate step of production.
Step 6: Grand Finale
In the final step, straps including the buckle, the adjustment system, and last parts such as the Aeroblade for the Gamechanger 2.0 are assembled by hand. Now the helmet has everything it needs for racing and training use.
Once again, handwork is important: Freed from the protective film, the helmet is ready for the final inspection. Every Abus helmet from the Italian factory is weighed and checked for visual defects and errors at the end, before being packaged for delivery. Only when the final inspection has been passed, does the helmet go on sale.
Hard Facts Gamechanger 2.0
| Versions: | Standard or with the new MIPS Air Node + Fidlock buckle |
| Aero Blade: | Special grid structure optimizes aerodynamics regardless of speed, side angle, and helmet tilt |
| Ventilation System: | With AirBoost air intake and Forced Air Cooling Technology for optimal head climate |
| Multi Shell In Mold: | For safe shock absorption |
| ActiCage: | Structure reinforcement integrated into the EPS to optimize stability |
| Half Ring: | Semi-enclosing, plastic ring connected with the adjustment system |
| Quin ready: | the helmet has space inside for an optionally retrofittable Quin chip |
| Zoom Pro: | Precision adjustable system with a grippy adjustment wheel that can also be adjusted in height – for an accurate and comfortable fit |
| Eyewear Port: | Aerodynamic eyewear holder with temple guide also at the back of the helmet |
| Ponytail Compatibility: | Helmet well suited for wearers with a ponytail |
| Made in | Italy |
| Visor: | No |
| Sizes: | S, M, L |
| Weight: | 260 g (S), 265 g (M), and 275 g (L) (+ 10 g for the MIPS version) |
| Price: | € 249.95 or € 299.95 (with MIPS + Fidlock) |
First Ride
During the short ride through the wonderful landscape around Bassano del Grappa, I let my thoughts wander once more. The Gamechanger fits me just as comfortably as my long-time companion the Airbreaker. For a moment, I think of the many hands on and off the machines that the helmet on my head has passed through, before the first fast descent requires my full concentration.
I make myself small like a hawk in a dive, or maybe a weasel fleeing into its burrow? In any case, I am fascinated by the acceleration that occurs simply due to the sudden reduction of wind pressure. A significantly smaller cross-section, an aero race bike like the BMC Teammachine beneath my rear, and an aero helmet like the Gamechanger 2.0, and off it goes, the mail!
Outlook
Meanwhile, seven helmet models from Abus are being manufactured in Italy. In addition to the new Gamechanger 2.0, the relatively inexpensive Wingback model is also coming to the market at €99,- (RRP).
The ranks of the Made-In-Italy models currently include the new Stormchaser and the classic Airbreaker and Powerdome, as well as the TT helmets Gamechanger Tri and Gamechanger TT. All information about the Abus innovations for 2024 can be found in our Abus Eurobike News.
The next big step for Abus will be the construction and commissioning of the new factory, when the currently four production sites, which are necessary to produce a helmet, will be merged into a new, larger, and process-optimized factory. We can look forward to the future products - and maybe in a few years, we will be able to catch a glimpse into the new production facility again ...
The Gamechanger 2.0 is already available at the following ABUS partners
- SPORT STREICHER: Pollheimerstraße 9, 4850 Timelkam, www.sport-streicher.at
- Sportradl: Ernst-Dreefs-Straße 2a, 4722 Peuerbach, sportradl.at
- Radshop Obersberger: Laabstr. 50, 5280 Braunau, radshop-obersberger.at
- Michi's Radladen: Moos 82, 5431 Kuchl, radladen.at
- Sport Rinnerthaler: Landstr. 50, 5231 Schalchen, www.sportrinnerthaler.at
- Loitz KG Zweirad-Fachgeschäft: Bundesstraße 95, 6923 Lauterach, www.loitz.at
- Zweirad Egger: Bahnhofstraße 53, 6900 Bregenz, www.zweirad-egger.at
- Mountainbiker: Bahnhofstr. 17, 9020 Klagenfurt, www.mountainbikerklagenfurt.at
- Probike: Prünster Amlacher Str. 1a, 9900 Lienz, www.probike-lienz.at
- Pedalhero: Beethovenstr. 3, 3250 Wieselburg, www.pedalhero.at
- Visit Bikestore GmbH: Radkersburger Str. 16, 8344 Bad Gleichenberg, visit-bikestore.com
- Zweiradfreude: Kremserstr. 18, 3123 Kleinhain, www.zweiradfreude.at
- Bernhard Kohl: Triester Str. 282-284/Top1/3, 1230 Wien, bernhardkohl.at
