3D-printed bicycle helmets

3D printing for the production of bicycle helmets

Cycling helmets are an essential contactor for every cyclist, but they are often mass-produced in standard sizes that do not fit every head - this is now a thing of the past. By using 3D scanning and additive manufacturing processes, bicycle helmets can be individually adapted to the shape of each cyclist's head.

This personalized production method not only improves the fit and thus the safety of the helmet, but also allows for greater flexibility in design-in. By capturing the exact dimensions of the head and integrating them directly into the production process, helmets are created that are optimized in terms of comfort and contactor.

Advantages of 3D printing for bicycle helmets

The advantages of 3D printing in the manufacture of bicycle helmets are manifold. First of all, this technology enables precise adaptation to individual head shapes, which significantly increases safety and comfort for the user. The direct transition from digital data to physical products eliminates conventional design-in restrictions, allowing more complex structures to be realized. Additive manufacturing is very efficient in terms of material usage, as only the material that is actually needed for the component is required in the end. And the speed of the manufacturing process should not be neglected either: It only takes a few days from the first scan to the finished product, which means that quick adjustments are also possible.

• Individual fit
• Freedom of design
• Efficient use of materials
• Fast production
• On-demand production

The integration of 3D scanning and additive manufacturing methods into the production process for bicycle helmets represents a significant improvement in user comfort. By using modern measurement techniques, individual head shapes can be precisely recorded and incorporated into the design process. This leads to an optimal fit of the helmet, which in turn maximizes the protective effect in the event of a fall. In addition, the flexibility of 3D printing allows complex geometries and ventilation systems to be integrated into the helmet design, which further increases wearing comfort. The rapid implementation from individual scan to finished product enables efficient prototype development and customized solutions for special requirements.

Use Case: SOLO

The SOLO use case represents a significant advance in the personalization and safety of bicycle helmets and impressively demonstrates the possibilities of 3D printing technology in modern product development. SOLO, a project designed by Nils Sorger specifically to meet the needs of individual users, uses the precision of 3D scanning to create helmets that are customized not only in form but also in functionality. This approach marks a paradigm shift in the manufacture of protective equipment, moving away from standardized sizes and instead offering a fully personalized solution.

At the heart of the SOLO project is the idea that no two heads are the same and that a helmet that is precisely tailored to the individual shape of a cyclist's head can offer significantly greater contactor protection and comfort. This insight led to the development of a helmet design that not only maximizes safety in the event of a fall, but also enhances the overall riding experience through improved ventilation and reduced weight.

3D scanning and customization

One of the core technologies behind SOLO, 3D scanning, enables unprecedented precision in the customization of bicycle helmets to individual head shapes. This process begins with a detailed scan of the head to capture exact measurements and contours. The resulting data forms the basis for the design process, ensuring a perfect fit. This individual adjustment not only improves wearer comfort by avoiding pressure points, but also significantly increases the protective effect of the helmet, as it fits optimally in the event of an impact and can distribute the impact forces more effectively.

Another aspect highlighted by SOLO's use of 3D scanning and customization is the ability to respond to specific user needs and preferences. This applies not only to the fit, but also to design wishes, which are made possible by the flexible design of the helmet. This achieves a new level of user satisfaction that is unparalleled in the production of bicycle helmets.

By using these innovative technologies, SOLO sets new standards in the safety and comfort of bicycle helmets. Customization ensures that every helmet is not just an item of protection, but also a personal product that reflects the identity of the cyclist and makes their ride safer.

Design and technical implementation

From digital model to physical product

Design process

Innovative aspects

Production process

By using Selective Laser Sintering (SLS), the design-in is built up layer by layer from a powder material. This technique enables exceptional attention to detail and is particularly suitable for the production of complex structures such as those required for the ventilation channels and the ergonomic fit of the SOLO helmet.

Technical specifications

Post-processing for optimum quality

After the printing process, the helmet undergoes various post-processing steps. These include the removal of excess powder, which is then reused to minimize material consumption.

The helmet is dyed after sandblasting to ensure uniform coloring and UV-resistance. By choosing a personal color preference, users are encouraged to wear it.

Bicycle helmets of the future

The SOLO project by Nils Sorger impressively illustrates the potential of 3D printing and individual design-in in the development of bicycle helmets. By using state-of-the-art technologies, it offers a customized solution that goes beyond previous limits in terms of safety, comfort and design-in. The approach of adapting each helmet to the unique head shape of its wearer not only represents a significant innovation, but also sets new standards for the entire industry.

Find out more about SOLO here >