An introduction to D3O
With a whole host of new materials and technologies, D3O has created this booklet with the latest information.
Who we are D3O® is a British-based impact protection solutions company that markets a unique patented technology that is used to produce a shock absorbing material. This high performing branded material is used to provide a wide range of integrated products in the motorcycle, sport, electronics, footwear and PPE markets. We were born out of the 2006 Winter Olympics, where we provided protective-wear solutions to the US and Canadian ski teams. With no compromise on protection, we changed the protection market with a range of light-weight, flexible and breathable protectors. Today, we continue to challenge and lead the world of impact protection and shock absorption with innovative, pioneering solutions for our customers. 3 How D3O works How D3O molecules work 4 How D3O works D3O materials in their raw state flow freely when moved slowly, but on shock, lock together to absorb and disperse energy, before instantly returning to their flexible state. This unique characteristic enables enhanced protection, while providing a versatile and flexible material that can be manufactured for a host of impact protective applications. We manufacture this raw substance into practical functionality, as both a foam and non-foam material. The technology allows freedom of movement for the user with no compromise in comfort or protection. As the materialâ€™s molecules lock, D3O disperses the force of impact, drastically reducing its effect and minimising the risk of injury or equipment damage. Note: D3O does not â€œgo hardâ€?. 5 The Solutions Provider D3O is a solutions provider. We work closely with our partner brands, offering full product development service from concept to design, and prototyping to testing and certification. Brainstorm Research & agree PDA Concept design & CAD Prototyping Performance analysis Final production 6 Testing and Accreditation We carry out extensive in-house testing, enabling us to assess quality and ensure stringent standards areÂ met. The D3O test lab includes an AD Engineering drop tower and Instron tensometer. A wide selection of our components meet CE standard requirements for a variety of applications. The D3O additional tests are always validated by independent labs to warrant authorised recognition of our components. These labs also perform tests which cannot be done in-house. 7 Our materials D3O is a smart, rate sensitive material â€“ the stress vs. strain characteristics are dependent on the rate of loading. This means that the harder the impact, the greater the resistance to the force. We engineer a number of dilatant materials and, using patented technology, incorporate them into polymer structures. We offer a range of material formulations, each developed to meet the specific needs of diverse market places and product applications. Property Application We manufacture and license our unique patented materials, combining enhanced chemistry and engineering to produce high performing, shock absorbing polymers. Sports Footwear Motorcycle Shock absorption Energy return Low density 8 PPE Electronics ST Solid Comparative impact perfornace at 10J Impact test based on EN1621-1 Transmitted force (kN) 40 30 20 10 Thickness (mm) 0 10 20 6mm Solid ST 4mm Solid ST 3mm Solid ST 10mm VN 20mm PE/EVA Foam 10mm EVA 10mm HDPE Foam 30 Mesh Comparative impact perfornace at 10J Impact test based on EN1621-1 ST is one of our soft, flexible and high performing material formulations. Focused on impact protection in a range of ambient temperature environments. Transmitted force (kN) 40 30 20 10 3mm D3O ST solid transmits 57% less force than 10mm EVA, despite being 60% thinner. Thickness (mm) 0 10 20 Typical Density (kg/m3) Typical Hardness (Shore 00) Available thickness (mm) ST Solid 400-550 60-75 3, 4, 6 ST Mesh 400-550 60-75 4, 6 9 6mm Mesh ST 4mm Mesh ST 10mm VN 10mm EVA 20mm PE/EVA Foam D3O Material 10mm HDPE Foam 30 Compared to 10mm EVA, 6mm D3O ST solid decreases the transmitted force by 79%. XT Solid Comparative impact perfornace at 10J Impact test based on EN1621-1 Transmitted force (kN) 40 30 20 10 Thickness (mm) 0 10 20 6mm Solid XT 4mm Solid XT 3mm Solid XT 10mm VN 20mm PE/EVA Foam 10mm EVA 10mm HDPE Foam 30 XT is a soft, flexible material focused on impact protection in a wide range of temperature environments. Mesh Comparative impact perfornace at 10J Impact test based on EN1621-1 Transmitted force (kN) 40 30 20 Compared to 10mm VN foam, 6mm D3O XT solid decreases the transmitted force by 80%. 10 0 10 D3O Material Typical Density (kg/m3) Typical Hardness (Shore 00) Available thickness (mm) XT Solid 400-600 60-80 3, 4, 6 XT Mesh 400-600 60-80 4, 6 20 6mm Mesh XT 4mm Mesh XT 20mm PE/EVA Foam 10mm VN 10mm EVA 30 10mm HDPE Foam Thickness (mm) 3mm D3O XT transmits 53% less force than 20mmÂ PE/EVA foam, despite being 85%Â thinner. 10 Shock+ Solid Comparative impact perfornace at 10J Impact test based on EN1621-1 Transmitted force (kN) 40 30 20 10 Thickness (mm) 0 10 20 Compared to EVA foam, 6mm Shock+ solid decreases the transmitted force by 73%. Comparative impact perfornace at 10J Impact test based on EN1621-1 40 30 20 10 3, 4, 6 Shock+ Mesh 500-700 70-85 4, 6 11 20 30 6mm Mesh Shock+ 70-85 4mm Mesh Shock+ 500-700 20mm PE/EVA Foam Shock+ Solid 10 10mm VN Available thickness (mm) 10mm EVA Typical Hardness (Shore 00) 10mm HDPE Foam Typical Density (kg/m3) Thickness (mm) 0 D3O Material 6mm Solid Shock+ 4mm Solid Shock+ 3mm Solid Shock+ 10mm VN Mesh Transmitted force (kN) 3mm D3O Shock+ solid transmits 61% less force than 10mm HDPE foam, despite being 60% thinner. 20mm PE/EVA Foam Shock+ is a versatile grade of impact protection for a range of extreme temperature environments. 10mm EVA 10mm HDPE Foam 30 D3O Aero Comparative impact perfornace at 10J Impact test based on EN1621-1 Transmitted force (kN) 40 30 20 10 10 20 D3O Aero 10mm VN 20mm PE/EVA Foam 10mm EVA 30 10mm HDPE Foam Thickness (mm) 0 We pride ourselves on our ability to produce low‑profile parts that still offer the ultimate in impact protection but also understand the market need for a lighter weight solution where weight is a key factor. D3O has developed a lightweight grade of polyurethane (PU), perfect for applications where weight is the primary material characteristic requirement. This high performing open cell PU solution lends itself to extended area coverage as it is soft and comfortable. At the same thickness, D3O Aero transmits 63% less force than vinyl nitrate and PE / EVA foam. Typical Density (kg/m3) Typical Hardness (Shore 00) Available thickness (mm) 200-300 60-75 Application dependent 12 D3O Lite 001 Comparative impact perfornace at 10J Impact test based on EN1621-1 Transmitted force (kN) 30 Thickness (mm) 40 10 20 10 0 20 At the same thickness, D3O Lite transmits 44% less force than traditional EVA foams. Typical Density (kg/m3) Typical Hardness (Shore 00) Available thickness (mm) 150-250 60-75 Application dependent 13 D3O Lite 001 10mm VN 20mm PE/EVA Foam 10mm EVA D3O Lite is our first EVA solution. Graded to enable a greater range of performance and material characteristics, D3O Lite is a cost effective, lightweight EVA which allows us to expand the integration of D3O impact protection into a wider range of applications. 10mm HDPE Foam 30 D3O Decell SATRA comparison between high grade EVA and D3O Decell 40 35 EVA Deceleration (g) 30 25 20 Decell 15 10 5 0 0 200 400 600 Compression cycles (thousands) Introducing D3O Decell - our latest material developed specifically for the athletic footwear market. D3O Decell brings strain rate sensitivity to the athletic footwear market. Walk and the D3O Decell offers cushioning, remaining soft and flexible, but start running and the D3O reacts to each impact, giving the user shock absorption that traditional EVA’s can’t match. D3O Decell deceleration stays low even at high impact energies while competitor results increase rapidly. ·· D3O offers better cushioning than high grade EVA’s ·· EVA loses 27% of its performance after 1000km ·· D3O Decell loses only 4% of its performance after 1000km 14 SATRA testing of D3O Decell: Repeated compression (SATRA TM156): Designed to simulate the compressive forces experienced during normal walking. Falling mass shock absorption (SATRA TM142): Designed to simulate the impact of a heel strike for a man running. Conclusions: Not only does D3O Decell offer a lower deceleration before any compressions are applied, it maintains performance throughout the whole test (see opposite page). While competitor materials fatigue as the compressions accumulate (the polymer structure degrading with each impact), our material remains durable and high performing, losing only 4% after 500,000 hits, theÂ equivalent of 1000km. Intelligent midsole Cushioning on impact 15 Typical Density (kg/m3) Typical Hardness (Shore 00) Available thickness (mm) 250-350 65-80 Application dependent Our technologies With a range of D3O materials now available, we have created a number of platform technology solutions aimed at disrupting the market place and providing innovation to market needs. Each D3O product technology solution can be tailored or moulded to suit the needs of the partner. We provide solutions to five very different markets. With our platform technologies, we are able to cater to the specific requirements of each customer inÂ eachÂ sector. Each technology is designed in-house and developed with protection, comfort and flexibility in mind. 16 Hooked Integration System Impact test based on EN1621-1 50 Ultimate impact protection maintained 40 Transmitted force (kN) Diameter of only 37mm Weighs less than a gram Level 1 pass 30 20 10 0 The profile of the product remains the same, despite the inclusion of hooked integration system Tighter integration into garments and no need for pockets or sewn parts D3O already manufactures streamlined, low profile, flexible parts. The inclusion of the Hooked Integration System within our range means that our parts sit even closer in the garment, combining the ultimate in impact protection with tighter, cost effective integration. 17 Ambient Wet Cold (-ยบ10) Example performance data based on the T5 ST Range D3O Smart Skin Comparative impact perfornace at 10J Impact test based on EN1621-1 Transmitted force (kN) 40 30 20 10 10 20 *D3O Aero material used D3O Smart Skin* 10mm VN 20mm PE/EVA Foam 10mm EVA 30 10mm HDPE Foam Thickness (mm) 0 The creation of D3O Smart Skin brings a new manufacturing process and integration method to the D3O range of impact protection. D3O Smart Skin is an innovative protective layer that allows even lower profile and more complex geometries than previously offered. It can be heat-bonded directly onto the surface of the garment so no need for pocketing or hook and loop systems. ·· Improved integration through heat bonding or sewing ·· Manufacturing cost savings ·· Exposed D3O components ·· Design printing on product capability ·· Abrasion resistance ·· UV resistance 18 Low profile Complex geometries Heat bonded Anti-abrasive laminate layer Example geometries 19 Reactor Fabric Base fabric + D3O Reactor Fabric Base fabric + foam Transmitted force (kN) Comparative impact performance Based on lab sample testing Reactor Fabric is D3Oâ€™s latest market-changing material innovation that sees 1-2mm of D3O impact protection applied directly to fabric at source. Ideal for applications where ultimately low profile shock absorption is key. D3O Reactor Fabric can be applied to a broad portfolio of fabrics commonly used across a wide range of market places and still incorporates D3Oâ€™s patented technology. D3O is a disruptive technology, constantly leading the market with new and innovative solutions. D3O Reactor offers superior protection to Neoprene, despite being 60% thinner. Applying D3O Reactor to a base fabric provides a 20% improvement in impact protection compared to other foamed fabrics. 20 How it works: Process: Fabric stretched on a conveyer belt and coated with D3O. Once cured, top layer then applied. The base fabric: Choose from thousands of fabrics. D3O Reactor: Lightweight, flexible, durable impact protection using D3O technology. The laminate: Top layer customisable to offer added value: ·· Abrasion resistance ·· UV protection ·· Fire retardency, etc. Laminate D3O Reactor Base fabric 21 Our products As well as developing bespoke solutions for our partners, we also design and develop components specifically tailored forÂ ourÂ targetÂ markets. Each component is tested to the highest standards to ensure the protection of the end user. 22 T5 Evo 50 40 Transmitted force (kN) The T5 EVO range of limb protectors offers great impact protection whilst remaining low profile and lightweight. They are CE certified to level 1 across ambient, wet and cold conditions and ideal for the motorcycle market. Level 1 pass 30 20 10 0 Ambient Knee Wet Cold (-ยบ10) PART NOMINAL DIMENSIONS (mm) NOMINAL WEIGHT (g) Knee 143 x 227 109 Elbow 130 x 222 96 Shoulder 140 x 185 95 Hip 130 x 179 75 Elbow 50 Transmitted force (kN) 40 Level 1 pass 30 20 10 0 Ambient Shoulder Wet Cold (-ยบ10) Hip 23 PART NOMINAL DIMENSIONS (mm) NOMINAL WEIGHT (g) Knee 143 x 227 84 Elbow 130 x 222 74 Shoulder 140 x 185 74 Hip 130 x 179 58 T5 EvoPRO 50 Transmitted force (kN) 40 Level 1 pass 30 Level 2 pass 20 The T5 EVOPRO range of limb protectors are even more durable than the T5 EVO range, with XT offering level 2 CE certification across ambient, wet and cold conditions and ST offering level 2 CE certification in all conditions. 10 Hot (40ºc) Cold (-10ºc) Wet Ambient 0 PART NOMINAL DIMENSIONS (mm) NOMINAL WEIGHT (g) Knee 143 x 227 153 Elbow 130 x 221 122 Shoulder 140 x 185 129 Hip 130 x 178 103 Knee Elbow Shoulder Hip 50 Level 1 pass 30 Level 2 pass 20 10 Hot (40ºc) Cold (-10ºc) Wet 0 Ambient Transmitted force (kN) 40 PART NOMINAL DIMENSIONS (mm) NOMINAL WEIGHT (g) Knee 143 x 227 130 Elbow 130 x 221 103 Shoulder 140 x 185 109 Hip 130 x 178 88 24 Xergo 50 40 Level 1 pass 30 Transmitted force (kN) Developed to exceed level 2 of the new standard in all conditions, the Xergo range of limb protectors offers greater protection across extreme temperature conditions (-10ºC to +40ºC) whilst remaining flexible and breathable. Level 2 pass 20 10 Hip Shoulder (left) Elbow Knee (right) 25 Hot (40ºc) Cold (-10ºc) Wet Ambient 0 PART NOMINAL DIMENSIONS (mm) NOMINAL WEIGHT (g) Knee 137 x 252 217 Elbow 118 x 249 184 Shoulder 167 x 218 190 Hip 149 x 222 167 Transmitted force T6 EN1621-1 Pass area Our T6 range of limb protectors have a built‑in hard shell offering puncture and abrasion resistance, whilst maintaining comfort and performance. The T6 range is CE certified. Time PART NOMINAL DIMENSIONS (mm) NOMINAL WEIGHT (g) Knee 143 x 227 113 Elbow 130 x 222 102 Shoulder 143 x 193 101 Hip 130 x 178 78 Knee Elbow Shoulder Hip 26 Crash range Comparative impact perfornace at 10J Impact test based on EN1621-1 The Crash Range was initially developed for the snowsports market but is now used in many applications, from mountain biking to motorcycles. Transmitted force (kN) 40 30 20 10 Thickness (mm) 0 10 20 Thigh Coccyx 27 6mm Solid ST 4mm Solid ST 3mm Solid ST 10mm VN 20mm PE/EVA Foam Kidney 10mm EVA 10mm HDPE Foam 30 PART NOMINAL DIMENSIONS (mm) NOMINAL WEIGHT (g) NOMINAL THICKNESS (mm) Thigh 143 x 227 153 8 Coccyx 130 x 221 122 8 Kidney 140 x 185 129 6 Viper Central 50 We have three back protector solutions, designed with an extremely flexible and breathable geometry known as Airwave technology. Transmitted force (kN) 40 30 Level 1 pass 20 The Viper Central gives the user high performing (EN1621‑2 level 1) spinal coverage. 10 0 Ambient Wet Cold (-º10) VIPER CENTRAL SIZE NOMINAL DIMENSIONS (mm) NOMINAL WEIGHT (g) TORSO LENGTH (cm) XS/S 137 x 339 187 Up to 43 M/L 165 x 400 262 Up to 50 XL/XXL 170 x 433 300 Up to 56 NOMINAL THICKNESS (mm) 13 Viper Central 28 Viper Stealth / Pro VIPER STEALTH At 18mm, the Viper Pro is our ultimate back protector solution and passes level 2 of the CE certification EN1621-2. Level 1 Pass area Transmitted force At 11m, the Viper Stealth is a lightweight back protector that includes protection for the scapula whilst remaining low profile. It passes level 1 of the CE certification EN1621‑2. Time SIZE NOMINAL DIMENSIONS (mm) Small 242 x 366 Regular 268 x 406 Large 274 x 444 NOMINAL WEIGHT (g) 228 277 332 TORSO LENGTH (cm) Up to 43 Up to 48 Up to 53 XL 316 x 477 386 Up to 56 NOMINAL THICKNESS CERTIFICATION (mm) 11 CE Certified EN1621-2 Level 1 Transmitted force VIPER PRO Level 1 Pass area Level 2 Time SIZE NOMINAL NOMINAL TORSO DIMENSIONS WEIGHT LENGTH (mm) (g) (cm) Small Viper Stealth / Pro 241 x 365 353 Up to 43 Regular 268 x 405 431 Up to 48 Large 274 x 444 492 Up to 53 XL 316 x 477 611 Up to 56 NOMINAL THICKNESS CERTIFICATION (mm) 18 29 CE Certified EN1621-2 Level 2 Accessories Comparative impact perfornace at 10J Impact test based on EN1621-1 Transmitted force (kN) 40 30 Our range of accessories includes market leading protective and shock absorbing components for the palm, knuckle, forefoot and heel. Metatarsal components offer great protection and performance characteristics in extreme temperatures, and are popular in footwear within the defence, workwear and sports markets. 20 10 Thickness (mm) 0 10 20 6mm Solid XT 4mm Solid XT 3mm Solid XT 10mm VN 20mm PE/EVA Foam 10mm EVA 10mm HDPE Foam 30 MET GUARDS SPECIFIC: Knuckle 50 Palm Clearance (mm) 40 30 20 10 Forefoot (right) 0 Heel (left) Boot with integrated D3O Met guard SIZE NOMINAL NOMINAL NOMINAL DIMENSIONS WEIGHT THICKNESS (mm) (g) (mm) STANDARD Small 128 x 104 52 10 Regular 134 x 108 56 10 Large 152 x 123 74 10 Small 122 x 89 37 10 Regular 134 x 98 44 10 Large 144 x 106 52 10 F16 Pre-curved met guard Standard met guard PRE-CURVED Left 138 x 121 73 13 Right 138 x 121 73 13 Please visit www.D3O.com for further information on our product ranges F16 met guard 30 D3O in a nutshell D3O: The Company Internal design team On-site sampling & prototyping capabilities In-house testing facilities Value adding marketing support D3O: The Materials High performance shock absorption Patented technology Maximum flexibility 31 Trusted protection Extremely comfortable Tested to the highest standards D3O Communications D3O is now the ‘secret ingredient’ technology found in many of the world’s leading sports brands. We are building a growing group of brand advocates across the sports world including elite athletes, engineers, leading brands and end users. Join us and Make An Impact. D3O Demo kit 32 D3O App, available on iOS and Android. Visit our website: www.D3O.com Join our community: 33 Testimonials “If people want to know about the quality of your armour tell them that they saved me when a giant truck ran over me... My arms, shoulders, and spine, all protected with your armor... uninjured, no bone breaks, no spine injury. It worked great. Thanks!” Rider in modified Triumph gear “If you’re thinking of investing in protective gear but think it’s too heavy or doesn’t look cool, think again. Today, lots of brands make lightweight, minimalist protection. That’s where D3O comes in.” Youri Barneoud, Onboard Magazine “Icon’s goal is to bring the very best of materials and construction to our products and D3O is an integral part of this process. The low profile of D3O armor and it’s industry leading protective properties allow us to provide our customers with apparel that is built to take a hit, but doesn’t interfere with mobility and movement - two very important things when piloting a motorcycle through the urban wasteland.” Icon “Thanks to the minimalist approach, it’s one of the best-fitting back protectors we’ve ever had the pleasure of riding in – ideal for races where a back protector is compulsory.” Mountain Bike UK D3O is cool, edgy and fun, but behind the day-glo orange exterior lies a product – and a company – with a serious grasp on technology, marketing and partnerships that is steadily turning into a global brand. Mike Peake 34 PPE Electronics Footwear Motorcycle Sports Our partners 35 Contact us: Sales: +44 1273 425 450 firstname.lastname@example.org Marketing: +44 1273 425 470 email@example.com www.D3O.com Press: +44 1273 425 459 firstname.lastname@example.org