The devil’s in the detail! How D3O’s new Diablo armour could change the future of rider protection

The world of motorcycle armour changed forever when D3O came onto the scene in 2009, and now the bar has been raised once again, with the brand releasing their most advanced kit to date.

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Called Diablo, the protective panels are said to offer next-level breathability, comfort, and flexibility – without compromising safety. So good are they, in fact, that the British brand have hinted the market may move towards a more stringent CE Level 3 standard in the future, although this is yet to be considered by certifying bodies.

MCN caught up with Design Lead, Adam Turvey, to find out how they’ve pulled it off – and what it might mean for protection.

Central to Diablo’s performance is D3O’s rate-sensitive material: a non-Newtonian polymer that remains easily malleable under normal conditions but instantly stiffens when subjected to impact. This allows for complex, lightweight geometries that absorb energy efficiently without adding bulk or limiting comfort.

Constructed from a new soft and ‘free-flowing’ IM material, this latest development in the company’s tech-based approach to safety offers a 38.5% open surface area and a svelte 9.5mm thickness in CE Level 2 form across moulded-to-shape panels. And if that’s not thin enough, there’s a minimalist 6.5mm Level 1 option.

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Diablo armour ditches traditional foam casting used elsewhere in D3O’s range in favour of injection moulding, hence the name IM material, calling upon a specially designed thermoplastic elastomer for the job. The firm says this allows them to push the envelope of thinness, while also giving them more room to tailor characteristics for certain applications. 

“Diablo is quite hard to beat,” Turvey states. “It’s your higher-performance, top-level armour.
“We’ve managed to take advantage of new tech to develop a grade that’s very soft and very flexible, and which allows us to design more complex structures.

“We’ve got our own in-house team of materials specialists, and part of their job is to constantly innovate, looking at the latest trends and newest materials.”

Pre-curved design

Unlike the firm’s flat, fabric-backed Ghost protectors aimed at casual riding kit, Diablo is pre-curved for a secure fit and designed with airflow in mind. The structure features a pattern of perforations and channels that aid ventilation, making it the coolest-wearing limb protector in D3O’s roster.

“Ghost’s main advantage is flexibility,” the engineer continued. “It’s our most fit-and-forget armour, but Diablo is close to being equal in that regard. [Yet] it’s softer and more breathable.”

He contrasts this with D3O’s older range: “With our old LP1 range, there were some manufacturing limitations. Some of the material options and techniques we’ve managed to bring onboard [for Diablo] have allowed us to open up breathability and flexibility.

“That brings us to the question of where to go now. We could make it even thinner, but I’m not sure anyone wants that.

“Maybe our next step is different protection levels, such as a Level 3. That might mean that Level 2 becomes our minimum, and doing that will benefit the user.”

Cross-industry expertise

D3O are also no strangers to cross-pollination between sectors. Their experience developing helmet liners for the US military has already informed their work on next-generation motorcycle head protection, which D3O previously revealed to MCN.

Planet friendly protection

Diablo uses around 20% less material to create than the brand’s older LP1 armour, significantly lessening its carbon footprint.

Custom fit

Thanks to D3O’s in-house chemistry team, the firm can formulate a product so it’s just right for the end
user. “There’s no magic wand that will cater for everything and everyone – products are made from multiple different materials and components for that reason,” said Turvey.

Formula One tech for your feet 

Beyond limb armour and helmet liners, D3O are also turning their attention to reducing rider fatigue using cutting-edge vibration-damping materials. 

Using a specific ‘AeroMax’ compound, the London firm have leveraged lessons learned in both Formula One and Nascar to release motorcycle-oriented insoles that reportedly mitigate vibrational forces transmitted through the peg to the rider’s foot – sharpening focus and reducing fatigue, whether you’re racing or smashing out big miles. 

Following an earlier release of vibe-cancelling mountain bike grips, a similar product for motorcyclists will be available to purchase soon, with similar benefits to their insole range expected.