Comfort Padding Engineer

Alpinestars is the leading global performance motorsports apparel, protection, and footwear manufacturer. For over 55 years the company has been providing the world’s best athletes and motorsports enthusiasts in the pursuit of performance excellence with the most technologically advanced products which fuse protection, innovation, and style.

Thanks to the outstanding quality and continuous innovation of our products, we are currently going through a solid expansion phase on the global market, for which we aim to reinforce our strongly international teams with top talent from anywhere in the world.

Position

We are currently seeking a Comfort Padding Engineer to join our Helmets Department, where you will lead the design & development of helmet interior comfort systems. The role will focus on achieving superior fit, ergonomic fit analysis, pattern design and supplier collaboration to develop advanced helmet padding for global markets. Depending upon projects, you will travel to meet suppliers and work closely with them.

Main Responsibilities

• You will design and develop comfort padding systems—including cheek pads, liners, crown pads, and neck rolls—for various helmet types.
• You will define 2D pattern layouts, seam placements, and construction logic, in collaboration with in-house or external seamstresses.
• You will select and validate materials such as foams, fabrics, and composites, based on mechanical and tactile performance criteria including density, softness, recovery, and moisture management.
• You will collaborate with EPS and CAD teams to optimize the interface between padding and EPS cavities (Expanded Polystyrene), ensuring best-in-class fit.
• You will analyze Western and Asian head morphologies to support helmet sizing strategy and shell’s fitting logic.
• Moreover, you will drive the execution of physical testing and user feedback campaigns in cooperation with internal & external laboratories to validate comfort and performance.
• You will investigate & apply innovative construction techniques, including thermoforming, high frequency welding, 3D shaping, hybrid material, to enhance functionality of product.
• You will be responsible for ensuring consistency and accuracy of BOMs, drawings, technical documentation, and sample records related to comfort paddings parts.
• You will perform competitive benchmarking and explore adjacent sectors—such as Motorsports and sportswear—for inspiration & technical solutions.

Requirements

• Bachelor/ master’s degree in Fashion/Textile Engineering, Biomedical Engineering, Materials Science and / or industrial design or related areas.
• A minimum of 3 years’ experience in product development of soft goods, ideally in helmets or high‑performance apparel.
• Previous expertise in patternmaking, as well as the ability to interpret and co‑develop shapes in 2D and 3D.
• Manual dexterity, confidence in working with physical samples and textile prototyping, basic use of sewing machines, as well as excellent understanding of different types of seams, their application and related constraints.
• Familiarity with thermoforming, high‑frequency bonding, layered textile construction and related material selection with the support of external suppliers.
• Good sensitivity to comfort, wearability, tactile feedback, and aesthetic alignment.
• Ability to analyze user feedback and a strong understanding of potential improvements, comfort & comparisons of different head fits of helmets.
• Strong attention to detail, critical thinking, strong trouble‑shooting abilities, proactive and self‑motivated approach, and a commitment to quality throughout all stages of the process.
• Excellent communication skills and ability to collaborate effectively at cross‑functional level with designers, engineers, and suppliers.
• Demonstrated collaborative mindset and ability to thrive in team‑oriented environments.
• Basic proficiency in Microsoft Office, PLM platforms (preferred), and 2D drawing tools.
• Willingness to travel based on project requirements.
• Excellent verbal and written communication skills in English.