A30
The A30 was conceived as a complete redesign of the A20, reimagining Bose Aviation’s flagship headset for the next generation of pilots. The goal was to honor the brand’s legacy while creating a more refined, durable, and comfortable product that bridges professional and consumer sensibilities. The design needed to perform across general aviation, military, and airline environments, introduce a tool-free boom mic system, and maintain a compact footprint. Beyond replacing the A20, the A30 would establish a platform for future expansion into broadcast.
Bose launched the A30 in 2023.
Understanding A20
Before we could design the A30, we first needed to understand the A20. What made it exceptional, why pilots trusted it, and where meaningful improvements could elevate the experience. This evaluation became the foundation for every design decision that followed.
Historically, comms earcup design language follows flagship consumer headset
Design Objectives
Evolve the A20 design while honoring Bose Aviation’s legacy and extending into prosumer markets
Consider the full system: headset, cables, control module, and case
Create a smaller, lighter headset and accessories while maintaining fit and comfort
Improve comfort through new materials, headband architecture, and flexible cabling
Balance durability and elegance to suit both commercial and aviation use
Introduce a tool-free, secure boom mic design for intuitive usability
Aligned on a center-spring headband
Iconic Bose Aviation feature
Maintained fit range from A20
Ear Cups
Evaluated numerous part and color breaks to help reduce visual weight and maintain continuity with the current consumer headsets
10% Weight Reduction
The drawback of the cast magnesium frames for A20 was the wall thicknesses that were required accounted for a significant amount of additional weight.
We discovered that with a machined aluminum frame we could increase the strength while reducing the weight of the part by over 10%
A30
Center spring architecture maintains the legacy of Bose aviation products and adapts to a wide tolerance of fit
Strong and approachable form – visual continuity is relevant across all use cases
Part splits were chosen to optimize visual size and reduce visual complexity
HEADBAND COVER
Bone lines on the headband cover help convey strength and continuity with the slider
YOKE
The yoke narrows along the arm to help reduce visual mass
TOOL-FREE LOCKING MECHANISM
Originally inspired by a dovetail joint, this mechanism was modified to employ two locking tabs that maintain a strong and stable connection within the earcup.
Smaller packaged than A20 mic housing
More integrated form
CONTROL MODULE
The control module progress through many iterations before arriving at the final form. The potentiometers that control individual volume of each earcup were a must have to maintain the same level of control as A20
