Bicycle helmets made to measure and in an affordable framework for everyone - what was unthinkable a few years ago is now becoming reality thanks to digitalization and additive manufacturing. The head is simply scanned with a smartphone app and the process for the custom-made helmet is initiated. Siemens, together with EOS, has supported this vision of the bicycle helmet manufacturer Hexr. Siemens' Digital Enterprise portfolio consists of software and automation solutions that optimize process steps along the entire value chain of additive manufacturing. This holistic approach is unique in the field of the industrialization of additive manufacturing. With the help of end-to-end solutions, Siemens has created the digital twin of an industrialized additive manufacturing factory, helping to optimize the design and streamline the production processes for customized bicycle helmets even before production begins. By combining simulation, design optimization and a high degree of automation in production, the costs per part could be predicted and significantly reduced, allowing Hexr to scale the scan-to-print application to mass production.