Anthony Ford from ZERO talks about the 10-year journey of the Apex helmet range, tracing its growth from a pioneering design to New Zealand’s most trusted industrial helmet. With first-hand insights into the engineering, safety standards, and innovations that have shaped the Apex helmets, Anthony reveals what sets ZERO apart in an industry where every detail counts.
Having been with ZERO for a decade, I’ve had the privilege of seeing the Apex helmet range grow from its inception to become New Zealand’s favourite industrial helmet. Over the last 10 years, the first-generation Apex Multi Pro helmet (APX05) has played a critical role in keeping New Zealand’s workforce safe. It’s become so widely trusted across industries that it’s now simply known as the "Apex O5." Over the years, I’ve watched as competitors have tried to imitate what makes our helmets unique, but those in the PPE landscape recognise that these alternatives are not always like-for-like.
ZERO’s standing as the creator of New Zealand’s favourite helmet is founded on the confidence of the country’s top PPE resellers, who choose our Apex helmets to protect their customers. For organisations, it’s more than just a product—it’s about engaging with PPE that inspires confidence and comfort. They specify our helmets because they know the quality and safety standards that come with the ZERO name, and that’s something I proudly stand behind.
10 years on and the Apex Multi Pro (APX05) still remails New Zealand's favourite industrial helmet.
What truly sets the Apex range apart is how we oversee every aspect of production. When it comes to manufacturing quality, we know our partners intimately—who to work with and who not to. We’re not just a helmet wholesaler; we design helmets, seek new technologies, and understand the manufacturing process. During my time in the industry, I’ve seen other importers try to capitalise on what we’ve built, focusing on volume over depth. For us, it’s crucial to understand the complexities of the production process to get the best out of a helmet.
One unique feature of ZERO helmets is how we manage the injection moulding process. Having been involved in development, I know that in injection moulding, the point of injection is typically the weakest spot. We strategically position this point away from the helmet’s crown, keeping the area that absorbs the most impact as strong as possible, particularly in crown impact testing. This is often an oversight by other manufacturers and, sometimes, visibly so. Some choose to inject at the top of the crown for convenience, but this compromises the helmet’s integrity right where it matters most. Our approach ensures that the Apex range delivers maximum protection during crown impact testing, which gives me the confidence to say our helmets perform where it counts.
A decade ago, we completed the iconic decal design for the Apex helmets. This unique decal has since become the hallmark of the Apex line, instantly recognisable as a symbol of safety.
Our commitment to continuous product development to enhance safety for New Zealand workers has led to the design of the second-generation Apex helmet, the Apex X2. It’s exciting to see how this reimagined model raises the bar in comfort, fit, and functionality. We know user acceptance is important, and that’s why the X2 truly looks and performs like an industrial helmet should. A comfortable and secure fit is vital, which is why the X2 includes both front and rear adjustments. We’ve made eye-shield attachments as simple as click and connect and created a direct-fit eye-shield cover for protection when not in use. The new Apex X2 isn’t just an update; it’s a response to the evolving needs of those who rely on it.
You can find out more about the second generation Apex X2 by ZERO here
The second generation Apex X2 was designed for the ever-changing industrial market, with a rugged design, fast-fit attachment points, and great adjustability for more head sizes.
In this crowded market, we focus on innovations that set the standard. Companies don’t choose ZERO just because we’re a wholesaler; they choose us because we bring unmatched expertise to every step of designing and manufacturing safety equipment. Every detail, from design to final production, is something I’ve been directly involved in, so I know that when professionals put their safety in our hands, they’re receiving a helmet built with their protection as our top priority.
For me, ZERO’s Apex helmets are more than just products; they represent our entire team’s relentless commitment to quality and safety. Industries across New Zealand trust them not only for their exceptional protection but also because they’re PPE that workers want to wear rather than have to. To date, it’s been an incredibly fulfilling decade in shaping the standard of head protection across New Zealand.