Helmet Fit System

RESEARCH  |  INDUSTRIAL DESIGN  |  ENGINEERING  |  PROTOTYPING  |  MANUFACTURING

Tool created Flux as a standalone venture to address a clear gap in head protection. Too often, helmet fit systems added bulk, pressure points, or complexity, leaving wearers uncomfortable or improperly secured. Flux rethinks that experience with the lightest, most adaptable full-head fit system on the market, engineered for comfort, simplicity and universal application.

At the core is Flux 360°, a patent-pending system that delivers full-head stability at just 50 grams. A dial-and-yoke mechanism ensures even tension with minimal cabling, snapping into EPS baskets or adapting seamlessly to hardhat webbing. The ambidextrous dial tightens in either direction, can be customized for branding, and even comes in a serviceable, Berry-compliant version for field repair.

The gains are significant: one size covers 90% of head shapes, eliminating multiple SKUs; adjustments are faster and easier, encouraging proper wear every time; and long-term comfort makes helmets more usable in real-world conditions, from construction sites to bike trails to military operations. Flux represents a new benchmark for protection systems—lightweight, versatile, and designed to raise expectations across every category.

FLUX 360°

Introducing FLUX 360°, our patent-pending full system that delivers 360 degrees of fit and comfort. At just 50 grams, it’s the lightest full-head fit system on the market—fully padded and customizable for any application. Designed to snap into EPS snap baskets or attach to a hardhat webbing system via our custom adapter, FLUX 360° combines a dial-and-yoke mechanism for exceptional stability and comfort.

With minimal cable exposure for maximum durability, FLUX 360° is also available in custom colors and branding. Experience the lightest, most comfortable, and most secure fit system on the market.

FLUX Yoke

The yoke is the crucial link between the dial and the fit system, offered in multiple configurations. For example, snow and bike helmets may use one style, while ballistic and military helmets require another. The yoke seamlessly connects to FLUX 360° or directly to a webbing system.

Our patented cable-to-webbing adapter ensures a clean, reliable transfer of dial force to the webbing system used in ballistic helmets—available in both bolted and boltless solutions.

FLUX Dial

Our patented dial is the engine behind all our fit solutions, which snaps securely into place. It’s easy to use, beautifully designed, and fully ambidextrous—tightening in either clockwise or counterclockwise direction. Whether you’re regular or goofy, we’ve got you covered.

The non-rotating center logo plate can be customized to showcase any brand, and a custom-shaped dial is also available as an option.

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