
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.