IonLeap in time - knee pads then and now

Laurin Lehner

 · 06.08.2024

Brand new: The Arcon Kneeguard LT from ION is designed to combine protection and comfort like no other knee pad.
Photo: Ion / BARTOSZ WOLINSKI
Mountain bikers started to protect their knees with protectors back in the 1980s. Back then with hard-shell protectors from motocross - later with special protectors for bikers. A look back and forward.

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1998 Knee and shin protector with hard plastic

Hard-shell knee pads from the early days of gravity biking.Photo: Georg Grieshaber / Mediengruppe KlambtHard-shell knee pads from the early days of gravity biking.
  • Pad: Hard shell
  • Certification: n.A.
  • Made in: Asia
  • Weight: 562 grammes
  • Price: 119 DM

If scene insiders are to be believed, Fox Racing was the first manufacturer to bring special knee protectors for mountain bikers onto the market. The US label from California adopted the design from motocross in the early 1980s. It was only later that manufacturers began to address the requirements of mountain bikers. While motocrossers primarily wanted to protect their shins and knees from whirling stones, mountain bikers prioritised comfort. After all, they had to crank, which required a more flexible connection between shin and knee protection. Brands such as Dainese, TSG, Axo and Raceface specialised in such protectors. Until late in the 2000s, hard-shell protectors dominated, even then in combination with simple foam inserts, which were used more for comfort reasons than for cushioning purposes. The protectors protected against stones, pedal pins and abrasions, but provided little cushioning on impact. It wasn't until the early 2010s that so-called memory foams were increasingly used, which hardened on impact, thereby cushioning and minimising residual forces.

Details Knee and shin protector with hard plastic

  • The hard shell principle was adopted from motocross. Advantage: efficient protection against flying stones. Disadvantage: hardly any cushioning in the event of a fall.
  • The pads can be secured with two elasticated Velcro straps. The helmet can be attached to this strap.
  • The Lycra sock provides an extra portion of support.
  • Elastic neoprene material serves as a connection between the knee and shin protectors for greater comfort when pedalling.

2024: Ion Arcon Kneeguard LT

MTB knee pads today: lightweight, ergonomic and with foam pads that provide maximum cushioning in the event of a fall. Here is the new Ion Arcon LT.Photo: IonMTB knee pads today: lightweight, ergonomic and with foam pads that provide maximum cushioning in the event of a fall. Here is the new Ion Arcon LT.

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  • Pad: RE ZRO
  • Certification: Protection level 2
  • Made in: Romania
  • Weight: 456 grammes
  • Price: 119,99 Euro

The new knee pad from Ion has little in common with the original model. Instead of a hard shell, the Ion Arcon LT Kneeguard uses structurally viscous polymers. This has two advantages: more cushioning and more comfort. But first things first: A project like this starts with a market analysis, as was the case with the Arcon Kneeguard. The aim was to develop a comfortable protector that you forget you are wearing, but which still passes the stricter CE EN 1621-1 Level 2 certification. In short: to combine comfort and safety. The team of six spent 18 months working on the finished product. This included product managers, product designers, CAD designers, fit specialists and test riders. During this phase, the team analysed numerous competitor products. For the padding, Ion opted for pads from RE ZROwhich, despite its narrow design, has a stricter protection level and therefore absorbs energy better in the event of an impact. For reasons of comfort, unnecessary seams have been omitted so that the protector moulds to the knee as softly as possible and does not pinch in the hollow of the knee. A nice side effect: the protector is made in Europe and produced in a climate-friendly way. ion-products.com


Our brand-new knee pad test series:


Trail knee pads should also offer comfort when pedalling. To prevent pinching in the hollow of the knee, manufacturers put a lot of thought into the design and avoid seams.Photo: IonTrail knee pads should also offer comfort when pedalling. To prevent pinching in the hollow of the knee, manufacturers put a lot of thought into the design and avoid seams.An extended pad covers the shin head. Ventilation holes ensure the right climate.Photo: IonAn extended pad covers the shin head. Ventilation holes ensure the right climate.

Details Ion Arcon Kneeguard LT (2024)

  • The pad is biodegradable. During production, special ingredients were added which, in combination with a microbe-rich and low-oxygen environment, promote decomposition. This means that the pad decomposes in compost within 3-5 years, according to the manufacturer.
  • The pad extends around the side of the tibial plateau and also protects the upper part of the tibia.
  • Together with ION, Re Zro has designed a pad that fulfils the strict requirements of the highest protection class (Level 2), yet still allows for a thin, comfortable design and is installed exclusively in the ARCON LT. There is space for the smartphone in a cleverly positioned side pocket
  • Extended silicone grippers at the top and bottom are designed to provide grip - the ventilation holes in the outer material provide the necessary ventilation.
  • The knee protector is made from a mix of recycled nylon, including hard-wearing Cordura material with 4-way stretch.
Brand new: The Arcon Kneeguard LT from ION is designed to combine protection and comfort like no other knee pad.Photo: Ion / BARTOSZ WOLINSKIBrand new: The Arcon Kneeguard LT from ION is designed to combine protection and comfort like no other knee pad.

Want more MTB history? Leap in time - MTB technology and accessories then & now

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Born in South Baden, Laurin Lehner is, by his own admission, a lousy racer. Maybe that's why he is fascinated by creative, playful biking. What counts for him is not how fast you get from A to B, but what happens in between. Lehner writes reports, interviews scene celebrities and tests products and bikes - preferably those with a lot of suspension travel.

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