paper to podium to production: How a product is made

Jérôme’s influence at Alpinestars is most visible in the Paragon vest – a lightweight, pedalling-friendly back protector that incorporates a hydration bladder and tool storage.

1. Initial idea Dutch racer Anneke Beerten was the first to suggest the idea of integrated back protection and water storage, when she made the switch from 4X to enduro.

2. Design From her request, the designers were presented with a brief of requirements for the product. The starting point was to produce 2D drawings and accompanying specifications. A tactical sheet was then created, showing the exact shapes of the panels, colours and branding.

3. Prototyping CAD software was used to make a pattern and cut out each piece. These were then sewn into a wearable prototype.

4. Lab testing The back protector was impact tested to ensure it conformed to the relevant safety standards and the fabrics were ripped apart and more to ensure they could withstand abuse on the trail.

5. Ride testing Testing by pro riders was a key part of the process. Feedback from Jérôme led to several changes, such as moving zips, adding protection from tools and altering the hydration tube routing. Further prototypes were trialled on the race track and new ideas fed into the final product.

6. Refinement New ideas and advances in technology mean the Paragon vest will be constantly revised – the designers’ work is never done!