Bringing racing technology to the consumer market: a digital platform for managing and tracking autonomous airbag systems
2017
By: Marte
Abstract
The Tech-Air Data Portal is the digital platform developed to manage the entire lifecycle of Tech-Air airbag devices. It was initially launched in 2013 to support the introduction of the Tech-Air Street system into the consumer market. Designed to translate complex technical processes into clear, usable tools for the Alpinestars dealer network, the project required a deep overhaul of business logic and operational workflows.
Managed using Agile methodology and continuous integration, the project resulted in a progressively disclosed interface capable of reliably supporting inventory, maintenance, configuration, and customer registration. Roles, permissions, procedures, and advanced search tools were unified into a single, scalable environment, reducing the margin for error and improving data quality.
The platform now centralizes product traceability and management for production, retailers, and end customers, transforming a disparate set of procedures into a coherent and integrated system. The project has also enabled Alpinestars to establish more robust processes and progressively extend the portal's adoption from the Italian and European markets to the United States, laying the foundation for the system's future growth.
Objectives
Background
Alpinestars is a company specializing in the production of technical gear and protective equipment for the motorcycle and motorsport industries. Among its most advanced solutions is Tech-Air, an autonomous airbag system integrated into riding apparel, which activates automatically upon impact to protect the rider.
Adapting a highly technical product for a much broader and more diverse audience.
Initially developed for professional racing, the company subsequently chose to introduce the system into the consumer market under the name Tech-Air Street. This transition required adapting a highly technical product for a much broader and more diverse audience, which demanded a full overhaul of production, distribution, and support processes.
Product lifecycle management, traceability, and the training of the sales and maintenance network became key strategic priorities, making the development of a dedicated digital infrastructure essential.
Purpose
The project's purpose was to equip Alpinestars with a unified platform capable of managing the entire lifecycle of Tech-Air Street devices—production, inventory, maintenance, and customer registration—ensuring a centralized and always up-to-date view.
The challenge was twofold: on one hand, to make highly complex technical data accessible and interpretable; on the other, to create a tool truly usable by different profiles (dealers, service centers, customer service, and headquarters) without requiring specialized expertise.
The system had to provide a clear, reliable, and up-to-date overview of the status of every device, ensuring traceability, process consistency, and a reduction in operational errors at retail points.
Method
The project was managed with a structured yet flexible approach, designed to adapt to a broad and continuously evolving technical domain.
We combined a thorough analysis of real-world processes with an iterative methodology to build a robust, user-friendly platform that perfectly meets the needs of all stakeholders involved.
Analysis
The project kickoff was dedicated to understanding the domain and the different types of users involved: dealers, service centers, customer service, and Alpinestars HQ.
The goal was to map the data structure, the real-world dealer processes, maintenance protocols, and customer service needs in order to build a solid, usable information model.
From this analysis emerged a particularly extensive information model, which required an initial phase of rationalization for practical deployment.
Making complex data accessible by simplifying technical processes and ensuring a consistent experience across the entire supply chain
Wireframe
Approach
The project was managed using a systemic and iterative method, shaping the information architecture to define roles, permissions, and contextualized views so that each user profile would only see what was relevant to their specific operational scenario.
On this foundation, we designed a progressive disclosure UX: the interface is structured on a clear left-to-right spatial logic, moving from a functional menu, to a device list, and finally to advanced detail screens, always maintaining clear context and avoiding cognitive overload within complex workflows.
An Agile methodology was adopted for the development, featuring short development cycles, continuous alignment meetings, and incremental releases in a shared environment. Each sprint introduced tangible improvements that were immediately tested with dealers and operators. This constant collaboration allowed the system to evolve coherently, progressively aligning with real-world processes and enhancing the product's robustness and usability.
Output
The resulting management tool is a platform that goes beyond simply organizing complex data: it redefines how dealers, service centers, and end customers interact with the Tech-Air ecosystem.
The interface, structured around a three-level layout, was designed to guide the user naturally from a high-level overview down to granular technical specifications; a persistent, adaptive sidebar acts as a cognitive anchor, while the central and right-hand sections expand and contract using progressive disclosure logic.
Device management has become a coherent workflow: inventory, service history, configurations and firmware updates are integrated into a single environment where every piece of information is presented exactly when it's needed.
The search function drastically reduces the time required to locate a device or critical information, supporting the operational style of dealers who typically don't navigate—they search, filter, and act.
Special attention was also given to the most sensitive steps, such as product registration by the end customer. The token-based process ensures traceability and security, transforming a potentially complex procedure into a straightforward, error-resistant workflow.
Overall, the Tech-Air Data Portal delivers an experience that does not hide the product's technical complexity, but rather structures, guides, and makes it usable through a clear, coherent, and scalable interface, designed to support critical operations and integrate seamlessly into Alpinestars' daily business processes.
It is more than just management software: it is a robust, modern working tool built to evolve alongside the needs of both the product and the organization.
Maintenance detail
Search tools
The search functions were designed to adapt to different usage contexts, reducing unnecessary steps and keeping the user focused on their task.
Contextual search provides immediate access to relevant information within the current section, while the global search extends queries across the entire system, offering a cross-sectional view of the data.
The interface was designed to integrate seamlessly into the workflow, creating a smoother and more intuitive search experience.
UX solutions
For production line users, the platform introduced digital tools to simplify and increase the precision of the Tech-Air system assembly process. The interface allows for the creation and updating of product records, the granular management of component serial numbers, and access to the latest technical bulletins.
For dealers, the user experience was designed to centralize product management and provide a real-time overview of customers, service records, spare parts, and service timelines, all while ensuring full privacy compliance. New search, tracking, and service request functions streamlined daily operations, reducing errors and response times while strengthening the connection between the company, its sales network, and end customers.
For end customers, the platform simplified the management of a technologically complex product, enabling them to register and monitor their devices, review service history, find the nearest retailer, and receive maintenance cycle notifications. Direct access to information and technical support helped promote more informed product use and build trust in the brand.
Security
The development of a unique token system for each Tech-Air product, generated at the point of sale, ensured the highest level of security for both customers and the company. It enabled buyers to register their device safely while preventing unauthorized registrations.
Testing
Direct testing within Alpinestars' own production department proved to be a critical project milestone. This hands-on approach allowed us to observe real workflows and pinpoint potential operational bottlenecks. The data gathered from these sessions provided essential insights, which we used to refine internal processes and finalize the technical and operational documentation.
Timeline
11/01/13
Kick-off
Project launch and preliminary analysis with the Alpinestars team and development partners
11/07/14
Release
Launch of the complete software platform, including tools for production, retailers, and customers
11/01/15
First evolution
Project expansion and enhancement of software tools for production and retail operations
11/01/16
Second evolution
Introduction of management tools and service queue optimization for devices
11/01/17
Business Intelligence
Integration of business intelligence systems for product and service data analysis
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Resources and technology
The project was developed through a structured collaboration across multiple teams and areas of expertise. In addition to our contribution to user experience design and functional workflow definition, the project involved internal Alpinestars specialists with deep knowledge of production processes and existing systems, as well as a dedicated technical partner for back-end development.
This synergy enabled the creation of a robust, scalable infrastructure built on a modular architecture, designed to support future evolutions and integrations.
Deep dive
The platform was developed as a single-page web application with a multi-user architecture, designed to deliver a fluid and consistent experience for production teams, retailers, and end customers.
The back-end is integrated with a relational database capable of managing complex entities such as devices, components, customers, service centers, and maintenance procedures.
A key element is the integration between the company's internal systems and the new web applications, achieved through a middleware component that ensures data consistency, real-time updates, and scalability across different markets.
The client-server architecture was designed to ensure a seamless user experience, secure data access, and the ability to release updates incrementally without disrupting dealer operations.
Results
Alpinestars successfully introduced the Tech-Air system into the consumer market, reconfiguring its internal processes and redefining its relationship with the retailer network. At the same time, the company built a digital ecosystem capable of guiding the end customer through the use of a technologically complex product.
We provided strategic and operational support for five years, managing all requirements related to market entry and working closely with the internal team and technical partners. Subsequently, the project continued to evolve autonomously, capitalizing on the technological and methodological foundations we helped establish and following the development and growth trajectories that had already been mapped out.
The implemented infrastructure enabled the management of processes from the Italian headquarters, with a progressive expansion first to the European market and then to the United States.
Conclusions
The Tech-Air Data Portal is a landmark digital transformation project that enabled Alpinestars to expand its highly technical product from professional racing to the consumer market.
The digital infrastructure we helped develop provided Alpinestars with the essential tools to manage the complexity of the Tech-Air Street airbag system throughout its entire lifecycle. The project successfully centralized the management of production and service processes, enhancing efficiency and reducing errors. This integration also resulted in a clearer, more intuitive user experience that simplifies product registration and monitoring for the end customer, strengthening brand trust.
Built on a scalable architecture, the platform was successfully rolled out from its initial Italian deployment to the European and US markets.
Our strategic and operational support during the first five years was crucial in establishing the solid foundation upon which the Tech-Air Data Portal could continue its autonomous evolution, cementing Alpinestars' position as a leader in innovation and safety within its sector.
