Aerospar began as my design research thesis for my Honours degree in Industrial Design. I noticed many motorcyclists riding without protective gear, despite the obvious dangers. I developed a three-stage research program:

1) Validate the Problem

I aimed to determine the proportion of riders without protection. Observations at three key arterial roads in Brisbane revealed that about 95% of riders lacked protection on at least one body part (head/neck, torso, hands, legs/waist, feet/ankles). Notably, up to 70% of motorcyclists wore no dedicated protection below the torso. These findings aligned with a review of the academic literature.

2) Establish Severity

I investigated the consequences of riding without protective gear using academic literature and statistical databases from Australia and the USA. This research showed that lower extremities were most likely to sustain injuries in accidents and often led to long-term or permanent disabilities. This finding emphasized the urgency of addressing the lack of protection in the lower body.

3) Identify Reasons

I collaborated with local recreational motorcycle clubs and conducted over 30 interviews with riders, each lasting 20-30 minutes. I employed a think-aloud protocol, questionnaire, and semi-structured discussion. These interviews confirmed the patterns of protective apparel coverage and highlighted commuters as the least likely group to use dedicated protection. When asked why, many cited the incompatibility of protective apparel with their destination (dressing for the destination, not the ride), while others mentioned the effort required to change before and after rides. Additionally, three observations of motorcycle parking areas during peak hours showed that riders in full apparel took significantly longer to depart after parking.
These findings informed a design brief for lower body protection that ensures use on every ride, regardless of the rider's clothing choice.

Concept Development

I used the research findings to outline a typical commuter ride action sequence. This analysis revealed that redesigning conventional rider apparel would unlikely address the identified problems. I reframed the question to, "What forms of rider protection can exist besides apparel?" and entered the concept generation phase, exploring wearable airbags.

Through low-fidelity prototypes using plastic sheets and nylon fabric, I developed a hollow cylindrical structure to surround the ankle and lower leg. The high-pressure outer chambers provide protection against point loads and abrasion, while the low-pressure inner chamber stabilizes the limb against torsional injuries and absorbs impact energy.

Further prototyping with clay and foam refined the chassis design, allowing for airbag storage and attachment to the rider's foot during use and to the motorcycle when not in use. Presenting this concept at the Industrial Design final year presentations earned me the Bob Taylor Award for Most Promising Startup and $10,000 AUD in seed funding from Bluebox, QUT’s technology transfer division.

I then incorporated a startup under the name Aerospar and further refined the concept using 3D printing for the chassis and experimental fabrics for the airbag. I successfully validated an airbag structure that can store around the foot and inflate to fully surround the lower leg, and I created a SolidWorks assembly inspired by contemporary motorcycle models. This iteration secured an additional $40,000 AUD in funding.

Lessons Learned

Although the project was not successfully commercialized, I learned valuable lessons. First, building a team around a project is crucial. A single person cannot handle everything; it’s essential to trust others' expertise and share the value of ideas.

Second, in starting commercial ventures, if you’re not growing, you’re shrinking. Securing funding must take priority until sustainable revenue streams are established. I did not prioritize this aspect sufficiently.