Learn about the unique processes that go into the manufacture of each HEXR helmet and how each element comes together to create the best fitting, safest helmet on the market.
“No two heads are the same, so why should helmets be?” is our oft-repeated mantra. In contrast to the limited number of sizes provided by mainstream helmet brands, the creation of your own personal helmet begins with a scan of your head with our app, which harnesses a 30,000-point 3D mesh.
This data is then sent to our cloud servers, where a helmet is automatically generated.
100% Plant Material
At HEXR, we manufacture our helmets from a plant-based material called Polyamide-11, made from 100% castor bean oil. This material is sourced sustainably by Arkema through the Pragati initiative, which supports sustainable farming practices, reducing water use, and fair treatment of workers
There are serious environmental concerns surrounding both the production and disposal of foam material, used in almost every helmet on the market. The castor beans we use are a viable alternative to petroleum feedstocks.
It’s an honour to be involved with the initiative and to be using Polyamide-11 to build the most sustainable bicycle helmet on the market.
The castor bean oil is converted into powder and sent to our 3D printing factory. Each helmet is 3D printed to less than a mm, following the contours of your head shape. We provide an offset to accommodate hair length and 'hot head'.
Our partners at 3T-AM in Newbury, UK, often produce parts for Formula 1 and Aerospace, and they take care of this tightly controlled step. Using a technology known as Laser Sintering, the helmet is produced layer upon layer by using high-powered and ultra-fine lasers to melt portions of consecutive layers of powder. The regions that have been melted later cool and solidify, whereas the surrounding areas remain in powder form which can be brushed away. The entire process takes approximately 36 hours for a batch of 6 helmets.
The Personal Touch
Having cooled for 72 hours following its 183°C build at 3T-AM, each helmet undergoes a rigorous finishing process to ensure optimal quality. First, all excess powder is removed using a combination of brushing by hand and blasting with tiny glass beads under high pressure. The powder removed in this step is recycled and will be used to print a future helmet.
Next, the honeycomb structure is dyed black before finally being visually inspected to verify its structural integrity and finish quality.
This dying process helps prevent UV light attacking the material over time, so that our helmets are can withstand years of action. That means more time chucking the bike around and less time worrying about whether your helmet is still up to the task.
The Finishing Touches
The final finishing touches include assembling the branded outer shell, chin straps, padding, and a voluntary ratchet system. Not only is your HEXR helmet custom made to fit your head, but we also add your own engraving, helmet size and the printing date to truly give it that personal touch.