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KAV Portola: KAZE 3D-Printed Bike Helmet Gets Stronger & Lighter Thanks to Proprietary PolyCarbon Filament

KAV Portola: KAZE 3D-Printed Bike Helmet Gets Stronger & Lighter Thanks to Proprietary PolyCarbon Filament

If you haven’t been paying attention, 3D printing is popping up everywhere in the world of cycling. From saddles , to dropouts , to yes,…

Friday, Nov 18

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If you haven’t been paying attention, 3D printing is popping up everywhere in the world of cycling. From saddles , to dropouts , to yes, even helmets . Among the companies creating helmets out of thin air, KAV has been leading the way with recent honors for their Portola helmet like a Red Dot award, a Design & Innovation Award, and one of Time Magazine’s Best Inventions of 2022.

And now, KAV is unveiling the next generation of their 3D-printed bike helmet, the Portola: KAZE. All images c. KAV When it comes to 3D printing, there are a number of things to consider, but one of the most important is the material itself. It has to lend itself to not only the printing process where products are built layer by layer but in this case, it also needs to perform well as an actual helmet.

According to KAV, the new Portola KAZE name is derived from the Japanese word for wind – a partial nod to the increased ventilation thanks to larger vents. But the big story here seems to be the material used to print the helmet itself, with KAV working with “the leading domestic provider of filament to compound and test over 20 proprietary co-polymers.” That search led to the sourcing of a new polymer from Japan which has been mixed with a proprietary blend of additives to create what they are calling KAV PolyCarbon.

This new filament material supposedly absorbs 35% more energy than typical EPS foam, and […]

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