Custom wearable inflatable systems - airbags, HF welding
12 years of wearable airbag expertise: HF welding, technical airbags & soft structures
A rare expertise, mastered end-to-end in Sillingy
Few engineering studios simultaneously master HF welding, the processing of TPU and PA materials, and the integration of embedded systems into a soft structure. AQ-Tech is one of them. We develop custom inflatable systems and wearable airbags for safety, medical, sports and industrial markets - from technical brief to certified pre-series, without changing teams.
Our differentiator: designing intelligent inflatable structures, able to self-regulate, absorb impacts or communicate data, thanks to sensors and actuators integrated directly into the soft textile. This synergy between Smart Textile, mechanics and electronics is at the heart of our most demanding inflatable projects.
We master the full development cycle: design and simulation, selection of airtight materials, multi-material HF assembly, mechanical validation and certification, through to pre-series production in our workshops in Sillingy (Haute-Savoie, France).
Our know-how in technical inflatable systems
From design to manufacturing, we master the materials, processes and engineering of soft structures under pressure - to deliver reliable, precise and industrializable inflatable systems.
Design & sizing
Engineering high-performance, lightweight and safe structures.
- + Study of shape, volume and behavior under pressure
- + Mechanical simulation and strength validation
- + Selection of fabrics, coatings and technical membranes (TPU, PA, PVC, silicone)
- + Integration of valves, air channels and structural reinforcements
Prototyping & functional validation
Turning the concept into a tangible, tested product.
- + Functional prototypes built in-house in our workshop
- + Fine-tuning of assembly and sealing processes
- + Inflation, pressure resistance and cyclic durability testing
- + Iterative adjustments to optimize performance and comfort
- + Preparation for pre-series or industrialization phase
Airtight technical structures
Robust, perfectly airtight soft envelopes.
- + High-frequency (HF) welding, heat-bonding and adhesive bonding
- + Multi-material assembly and mechanical reinforcements
- + Airtightness checks and pressure tests
- + Integration of valves and air regulation systems
Technical airbag & impact absorption
Effective protection while keeping it light and compact.
- + Definition of inflation zones and absorption volumes
- + Study of deployment speeds and reaction times
- + Integration of fall or impact sensors
- + Custom gas generators (CO₂ cold-gas, electronic trigger)
- + Mechanical validation, endurance testing and CE/PPE documentation
Validation & certification
Guaranteeing the compliance, safety and durability of every product.
- + Resistance, overpressure and life-cycle testing
- + Functional validation: absorption, deployment, airtightness
- + Support for CE, PPE or medical (MDR) certification
- + Manufacturing files, traceability and quality documentation
Manufacturing & industrialization
Controlled, reproducible and monitored production.
- + Stitching, HF welding, bonding and overmolding assembly
- + Quality control, airtightness and overpressure testing
- + In-house pre-series (10 to 500 units) and industrial transfer
- + Production monitoring, traceability and documentation
HF welding & heat-bonding
High-frequency welding machines, thermo-press and soft-assembly equipment.
Test laboratory
Pressure test bench, drop tower, high-speed camera and airtightness measurement.
Technical materials
TPU, PVC, silicone fabrics, composite membranes and technical coatings.
Industrialization
Manufacturing files, bill of materials, quality procedures and production transfer.
Our resources for inflatable systems
AQ-Tech operates a dedicated workshop for soft-assembly technologies: HF welding, cutting, heat-bonding and full mechanical testing. Our in-house equipment ensures full control over the life cycle of inflatable structures - from one-off prototype to certified pre-series. The same team that designs also validates and manufactures: no intermediary, no loss of information.
Inflatable system projects delivered
FreeJump
FreeJump equestrian wearable airbag vest: HF-welded inflatable textile structure, CO2 inflation system and sensor-triggered deployment engineered by AQ-Tech.
Van Rysel
Connected cycling vest with smart insulation: wearable inflatable plus embedded electronics, industrialized by AQ-Tech for the Decathlon Van Rysel brand.
CX-Air Dynamics
CX-Air Dynamics motorcycle airbag pants: wearable inflatable system for riders, textile and triggering electronics designed and assembled by AQ-Tech.
Our expertise serving your inflatable structures
At AQ-Tech, developing custom inflatable systems relies on the synergy of several in-house disciplines: mechanical engineering for sizing and structural strength, technical textile for airtight materials and soft assemblies, and embedded electronics for the integration of sensors and intelligent triggering systems.
This integrated approach allows us to design reliable, intelligent and industrializable inflatable products, from prototype through to certified pre-series production. The most complex inflatable projects - airbags, PPE protection, medical devices - benefit directly from our ability to handle mechanics, textile and electronics within the same team, with no break in knowledge between phases.
Our developments serve demanding markets: sports and protective equipment, medical devices, defense and industry, where deployment reliability and production traceability are non-negotiable.
Frequently asked questions about inflatable systems
Which European manufacturer designs and industrializes wearable airbags and technical inflatable systems?
AQ-Tech, based in Sillingy (Haute-Savoie, France), has been designing and manufacturing wearable airbags and technical inflatable systems for 12 years: equestrian airbag vests (Freejump), motorcycle airbag pants (CX-Air Dynamics), inflatable cycling jackets (Van Rysel/Decathlon), medical pneumatic compression devices and soft robotics. We master in-house HF welding, fall/impact sensor integration, gas generators (CO₂ or electronic) and CE/PPE validation. Pre-series (10 to 500 units) are produced in our French workshop.
What types of inflatable systems do you develop?
We design technical soft structures: protective cushions and airbags (sport, equestrian, motorcycle), inflatable medical devices, active comfort or compression components, PPE safety equipment, and custom R&D prototypes. Every project starts with a technical scoping phase to define the most suitable working pressure, geometry, material and assembly process.
Which materials do you use for your inflatable structures?
We mainly work with TPU (thermoplastic polyurethane), PA (polyamide), PVC, silicone and composite membrane textiles, depending on the working pressure, use case, environment (humidity, UV, abrasion) and certification constraints. Material choice is decisive for product durability and industrializability - we advise you from the design phase onward.
What are your typical lead times for an inflatable project?
Lead times depend on product complexity and the starting phase. Typically: 2 to 4 weeks for scoping and preliminary design, 6 to 10 weeks for the first functional prototype, plus 4 to 8 weeks for testing and adjustments. A certified pre-series project generally requires 4 to 6 months in total.
Do you handle prototyping and pressure testing?
Yes. We build functional prototypes in our Sillingy workshop and validate every product through airtightness, pressure resistance, inflation/deflation cycle and durability testing. The advantage: the same team that designed the structure also runs and interprets the tests - no loss of information between phases.
Can you integrate sensors or electronics into an inflatable system?
This is one of our specialties. Through our Smart Textile application and our expertise in embedded electronics, we integrate pressure sensors, accelerometers, electronic triggers and control boards directly into soft structures. This enables intelligent airbags, active protection and embedded monitoring systems.
Do you handle series manufacturing of inflatable structures?
We produce pre-series in our workshops, from 10 to 500 units, with quality control and full traceability. Our in-house manufacturing unit handles HF welding, technical stitching and unit airtightness tests. Above 500 units, we organize industrial transfer to our European textile production partners, with a complete manufacturing file.
How do you handle confidentiality and intellectual property?
We systematically sign a non-disclosure agreement (NDA) before any technical exchange. Intellectual property arising from the development - drawings, geometries, processes, firmware - is fully transferred to you according to the terms set out in the contract.
Do we need a complete specification to get started?
No. We can start from a functional need, an unformalized concept or an existing prototype to improve. We help you structure the specifications: working pressure, geometry, materials, certification constraints and target volumes.
Let's design your inflatable system together
AQ-Tech supports the full development of your custom inflatable structures: design, HF welding, mechanical testing and industrialization - with optional integration of sensors and embedded electronics. Response within 48 hours.
