3D-printed custom bicycle helmets  3D-printed custom bicycle helmets

Siemens Magazine | Dec 1, 2020 at 5:16 PM

EOS is the world’s leading technology and solution provider for industrial 3D printing of metals and plastics. The independent company founded in 1989 is a pioneer and innovator of integrated solutions in additive manufacturing. The company is headquartered in Krailling near Munich, Germany.

HEXR was founded by engineers, among them Jamie Cook, who were frustrated that bike helmets hadn’t seen significant innovation in over 30 years. The helmets were researched and developed at the University of Oxford and crafted with aerodynamics partner British Cycling. The company is headquartered in London, UK.

HEXR helmets are built on a honeycomb structure that’s significantly better at controlling impact than foam. Each helmet is created to the precise contours of the rider’s head and 3D printed from data that’s accurate to within a hair’s breadth. As a result, these helmets optimally protect the most sensitive areas. At the same time, the helmet’s structure makes it so lightweight that “You can forget it’s there,” says HEXR’s Website, describing what’s claimed to be the world’s first custom bicycle helmet.

“Standard foam helmets absorb only about 30 percent of impact energy,” says Cook, “mainly because they were designed for flat surfaces, not naturally curved surfaces like our heads. That’s how we arrived at the idea of a curved, honeycomb structure manufactured on a 3D printer”. Cook and his team later developed a 3D-printed helmet that can absorb twice as much energy as a standard helmet with a foam core.

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