Redwood City, California (BRAIN)-KAV Sports, which has been selling custom 3D printed hockey helmets since last fall, is launching a 3D printed bicycle helmet, and the crowdfunding campaign started on Tuesday.

The company stated that the structure of the helmet provides a customized fit while minimizing volume to improve aerodynamics and lightness. A few years ago, a British company called HEXR launched a customized 3D printed bicycle helmet, but it was not certified by American standards, so customers here could not use it.

Interestingly, both HEXR and KAV use additive technology to create a honeycomb-shaped hexagonal unit in the helmet lining. Specialized's 3D printed saddle S-Works Power with Mirror uses a similar hexagonal honeycomb. 

KAV founder and CEO Guo Huimin explained to BRAIN that this is no coincidence. "When you analyze their energy absorption to weight ratio, the hexagon is one of the most effective structures," he said.

The 3D printing pad enabled KAV to create an energy management system that reduces rotational acceleration. The inner lining is also about 20% lighter than EPS; a complete helmet weighs less than 300 grams in almost all sizes, while providing more head coverage than some helmets. In contrast, some ultra-light road helmets like POC Ventral Light weigh less than 200 grams, but most mid-priced helmets are in the 300-400 grams range.

KAV customers will receive a Fit Kit to measure their head before ordering. The kit records the circumference and approximately six other measurements. Kav inputs these numbers into machine learning algorithms to generate virtual renderings of the client's head, including specific roundness, forehead tilt, and other factors. Then the 3D printer produces a unique shell and lining for each customer. The helmet is designed and manufactured in the U.S.

In the hockey market, KAV collaborated with Sharks hockey stores to provide customers with measurement data, and Kwok said he would be happy to work with select independent bicycle stores in a similar way.

"In the United States, from research and development to materials to labor, our helmets are more expensive to manufacture in all aspects. Therefore, our choice is to find a store that we can certify on the one hand, and on the other to ensure that we can promote Enough sales to make it worth a try," he said.

Because the helmet fits very well, the company can reduce the complexity of its fitting system and further reduce weight. 

Guo said the company has cooperated with the US Consumer Product Safety Commission to certify the design. Although some helmet standards require a test for each size of the model; Kwok said that KAV's software ensures that each helmet has the same offset, so no matter what the custom shape is, it can pass the test. Kwok also conducts sample tests on a regular basis.

The helmet will be offered to Kickstarter supporters at a price of US$275, with a suggested retail price of US$375. In the first few hours of Tuesday, the Kickstarter campaign surpassed its goal of US$10,000, 37 supporters pledged more than US$15,000, and the campaign has 35 days left. 

Kav plans to start shipping helmets to supporters in November.

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