ZYON Helmets
The first helmet against air pollution
ZYON is developing the first helmet with an integrated filtration system to ensure the driver can breath clean air.
At VFluid Advanced Technologies, , we thrive on solving complex engineering challenges through simulation and experimental testing. Our recent collaboration with ZYON, a forward-thinking company developing a helmet with integrated air filtration, was no exception.
The goal was clear: create a helmet that ensures a supply of clean air to the driver in demanding environments. Our role was to support development using advanced CFD tools, guiding the design with data-driven insights.
The Challenge
Designing a helmet that integrates a filtration system poses significant aerodynamic and ergonomic challenges. Air must be directed effectively through the filter and into the breathing zone without creating discomfort while inhaling/exhaling while avoiding thermal imbalances. Ensuring uniform distribution and managing the internal flow paths at the different use cases were critical from both a safety and comfort perspective.
Our Approach
We adopted an iterative development process using Computational Fluid Dynamics (CFD), starting with 2D simulations to quickly understand general flow behavior and identify any problem areas. These early simulations helped us understand the limitations at each of the working scenarios (inhalation/exhalation, stationary vs in transit) and focus on key design parameters such as intake geometry, channel curvature, outlet locations and flow management strategies.
Once we refined the concept, we moved into 3D simulations to capture the full complexity of flow interaction around the helmet and within internal ducting. This phase allowed us to assess the performance more accurately and propose targeted modifications.
Key Results and Insights​​
CFD simulations revealed important opportunities for improvement, such as:
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Optimizing inlet shapes to reduce pressure drop and ensure that the air was evenly distributed across the filtration area.
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Optimizing the internal ducting distribution to ensure thermal balance and reduce stagnant flow which could compromise breathing behavior.
These insights drove several design changes that not only enhanced performance but also supported manufacturability and user comfort.
Looking Ahead​​
As the project moves toward prototyping and physical testing, our findings provide a strong foundation for validation. This collaboration exemplifies how early-stage simulation can accelerate development and reduce uncertainty in hardware design, especially in high-stakes applications like personal protective equipment.
Trusted by the Best
Beyond our Formula 1 experience, VFluid Advanced Technologies is the official FIA partner for aerodynamic homologation in the World Endurance Championship (WEC). This trust from the governing body of global motorsport is a testament to our technical excellence and commitment to precision. When you work with us, you are not just hiring an engineering consultancy - you are gaining access to the same expertise, tools, and know-how that drive the pinnacle of motorsport performance.
Bringing F1 Technology to Your Project​​
One of the key advantages of partnering with VFluid Advanced Technologies is the opportunity to integrate F1-level technology into your project, whether it be a racing team, a hypercar manufacturer, or an advanced mobility initiative.
The resources and expertise that are typically out of reach for most companies become accessible through our consultancy, enabling you to compete at the highest levels of performance and innovation.
Contact Us Today​​​
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Partner with the team trusted by the FIA to deliver motorsport-grade performance and cost-efficient solutions to your project.
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Whether you're an motorsport team looking for aerodynamic development support, a hypercar manufacturer aiming to push the boundaries of performance or a technology-driven enterprise seeking cutting-edge expertise, VFluid Advanced Technologies is your gateway to elevate the aerodynamic performance of your project to the next level.
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Contact us today to discover how we can bring our F1 and FIA-backed expertise to your project.
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