GoPro Mount
Product Design · 3D Print
Client:
Personal Project
Role:
Product Designer
Year:
2025
New Olders Blackbird V2 helmet GoPro chin mount
involving the design, prototyping, and testing of a custom GoPro mount.
Challenge
The helmet has an irregular shell geometry which makes Standard GoPro mounts difficult to grip reliably
I could tell other riders had figured something out — but I didn't know how, and copying blindly wasn't the point.
I wanted to understand the problem and solve it my own way, with whatever I had available.
I had 3D modeling skills and a printer. That was enough to start.
Approach
How do I fix this without ruining the helmet?
I wanted to design a made-to-measure clip that fits securely, without drilling or permanently modifying the helmet, while staying easy to attach and remove.
I defined my success criteria before touching any tool:
Performance
Stable footage
Repeatable positioning
Heat & wet resistant
Fit & Safety
Helmet-safe contact
No surface damage
Ventilation slots unobstructed
Non-obstructive placement (Ergonomics)
Compatibility & Accessibility
Action cam standard compatibility (GoPro / Insta 360 / DJI)
Easy to print
Tool-free attachment
Time to build
I followed an iterative prototyping process — validating three key factors:
Buckle interface compatibility
Helmet geometry fit
3D printing constraints
Key Decisions
Compound curve fit
The Blackbird V2's chin bends in two directions simultaneously. The base had to be modeled with a concave geometry on two axes — a single-curve solution wouldn't sit flush.
Prototype strategy
10 iterations across four focus areas: buckle interface geometry, helmet fit, base scale, and print parameters. PLA for speed during validation, TPU 95A for the final version.
Material choice
TPU 95A over rigid materials — flexible enough to absorb vibration and conform slightly to the surface, strong enough to hold under speed, light enough not to affect balance.
Attachment options
Two systems were tested: 3M tape for a permanent setup, Velcro for riders who prefer a cleaner helmet when the camera isn't needed.
The Velcro option was also a validation decision — confirming it could hold reliably under real riding conditions before recommending it.
Print orientation
Printed vertically to eliminate the need for supports, reducing material use without compromising structural integrity at the critical contact points.
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