KAV
Hockey Helmet
World’s first 3d printed hockey helmet
The KAV hockey helmet is the world’s first custom fit 3D printed hockey helmet.
KAV’s main goal is to solve the problems of helmets that go hand-in-hand: creating a good, comfortable fit that also ensures concussion safety.
KAV wants to create the best experience by focusing on the following characteristics:
Design from the ground up to reduce rotational and linear accelerations.
Personalized fit, to accommodate not only many head sizes but also head shapes.
Lighter weight, to minimize fatigue and encourage heads-up play and situational awareness.
Extensive ventilation and non-insulating materials, for unmatched thermal regulation which also minimizes fatigue.
Completely integrated fasteners, to eliminate bolts that rust, break or occupy critical space in potential zones of impact.
Create Starting with the first hockey helmet to achieve a five star safety rating.
sketches
Early form exploration
After the sketching phase soft modeling clay was used to rapidly explore different forms and get an idea of spatial volume and which helps to see how the helmet forms sit on the human head. The clay mockups were made to ¼ scale.
mock up development
After form exploration through soft clay, more detailed mockups were from hard Chavant clay and high density foam. Once the form was develop it modeled in clay to full scale and then 3D scanned to produce a 3D model.
3d printing protoypes
field testing
A full featured prototype was 3D printed and then tested by actual hockey players on the ice for fit, feel, comfort, protection and durability.
