Sergiu PărgrasIndustrial designer
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Product design · Ergonomics · Protective equipment

WeldLite

Year
2019
Three front and interior views showing the WeldLite shell, visor, and adjustable harness

WeldLite is an industrial design thesis that rethinks protective welding gear around the changing needs of the wearer. The project brings grinding and welding into one adaptable system while improving ergonomics, sightlines, and protection in demanding workshop environments.

One helmet, two workflows

The modular visor combines a clear panoramic shield with an integrated auto-darkening filter. Moving between grinding and welding no longer requires changing equipment, while the expanded opening preserves peripheral vision for detailed fabrication.

Built around the wearer

An anatomically balanced shell and adjustable internal harness distribute weight across the head to reduce neck fatigue. Side-mounted routing supports powered air-purifying respirators, while the shell geometry directs sparks, spatter, and radiant heat away from the face and throat.

WeldLite project presentation · 02:15
Front and side technical views defining the proportions of the WeldLite helmet
Front and side views establish coverage, sightlines, and clearance around the wearer.
Side and rear technical views defining the dimensions of the WeldLite helmet
Rear and profile dimensions complete the helmet's spatial definition.
Technical drawings showing WeldLite visor and shell components
Component drawings translate the helmet's layered construction into manufacturable parts.
Dimensioned technical drawings of WeldLite helmet components
Critical dimensions coordinate the shell, visor, and internal mechanisms.
Exploded view of the WeldLite modular visor and protective layers
A layered visor bridges grinding and welding without requiring a change of helmet.
WeldLite harness tension and rotation adjustment views
Independent tension and rotation controls adapt the fit around the wearer.
Exploded rendering of the adjustable WeldLite internal head harness
The internal harness distributes weight and supports precise adjustment around the head.
Rendered front, perspective, and interior views of the completed WeldLite helmet
The resolved helmet combines a panoramic clear shield with an auto-darkening filter.
Detailed renderings of the WeldLite pivot, locking mechanism, and adjustable shell
Side pivots coordinate visor movement, shell adjustment, and repeatable locking positions.
WeldLite development board showing visor movement, weight balance, prototypes, and ergonomics
Full-scale mockups tested balanced loading, peripheral vision, and movement around the face.
WeldLite project overview showing its form, construction, and use
The complete proposal brings its protective, ergonomic, and mechanical systems together.
WeldLite helmet form evolving from a cardboard volume study into refined digital models
The shell developed through physical volume studies and successive digital refinements.
Sergiu Părgras presenting and wearing the physical WeldLite prototype beside the development boards
The full-scale prototype was presented alongside the development drawings and component studies.
Welder wearing the WeldLite helmet while grinding metal amid a field of sparks
The clear panoramic shield protects the face while preserving visibility during grinding.
Welder using the WeldLite helmet under blue workshop light
The integrated auto-darkening filter supports welding without changing protective equipment.
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