Back Protector Development & Manufacturing

This project involves the development and industrialization of a removable back protector, integrating rigid structural protection with thermoformed comfort components within a complete OEM manufacturing process.

The protective shell was engineered in recyclable PE and manufactured through injection molding. The component was subjected to impact testing to verify compliance with EN1621 standards, ensuring structural performance under real-world conditions.

The supportive harness system was developed by integrating textile components with the rigid shell using thermoforming and stitching processes. This required coordinating multiple manufacturing techniques to achieve an ergonomic fit combining soft support structures with the hard protective element.

Each component was tested prior to final assembly. The entire development process was managed internally, from 3D CAD design and prototyping to tooling and full-scale mass production, ensuring control and consistency across every phase of the product lifecycle.