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London-based HEXR Along with Partners Reinvents Cycling Helmets Production and Supply Chains with EOS 3D Printing

EOS 3D printing HexR helmet
EOS 3D printing HexR helmet
Above: 3D printed cycling helmet by HexR/Image Credit: EOS

EOS, the world’s leading technology supplier in the field of industrial 3D printing of metals and polymers announced that it has been supporting London-based HEXR with its technology and providing expert consultancy since 2015. With the introduction of the HEXR fitting app, the company is now offering a complete scan-to-product-solution for high quality, safe 3D printed cycling helmets.

An app-based head scan allows customers worldwide to begin the bespoke cycling helmet creation process at home.

3D printed cycling helmet
Above: Custom-fit, with 3D printed cycling helmet with honeycomb structure/Image Credit: HEXR

Next, the helmet is 3D-printed with EOS technology in a 100% plant-based polyamide material produced exclusively by Arkema. It is then dyed in black before final inspection for structural integrity and finish quality. Finally, all components of the helmet—including the 3D printed inner structure, outer shell, chinstraps, etc…—are assembled, custom fit to the cyclist’s head and with an optional individual touch (e.g. personal engraving and shell colour).

Speaking about how the company has been supporting HEXR, Markus Glasser, Senior VP at EOS, EMEA said, “Besides consulting, we’re excited to support HEXR with our industrial 3D printing production technology, ideally suited to HEXR’s business model and products. Together with a fast-growing network of established partners, such as Siemens and Arkema, we enable a digitalized and distributed manufacturing process with high-quality parts that can be 3D printed where they are needed—on-demand and tailored to our customers’ requirements.”

“HEXR is an example of a more flexible supply chain and production technology in action, and we see many similar business cases emerging in other industries too,” adds Glasser.

Offering details of how the HEXR has been improving helmet technology with 3D printing, Jamie Cook, CEO at HEXR states, “With custom-fit intrinsic to this leading-edge manufacturing process, and superior independent safety test scores compared with traditional foam helmets, we are enabling major improvements in helmet technology made possible by 3D printing.”

Henry Neilson, CTO at HEXR adds, “Based on this technology, we have a low-risk and very efficient scan-to-product solution, avoiding any pre-financing of products, minimum production quantities, or over-production. As such, we can completely focus on our key competencies, whilst relying on established production processes.”

Both Arkema and Siemens have contributed their expertise to HEXR’s Integrated Scan-to-Print Solution. “Arkema is a world leader in high-performance polyamide 11 polymers derived entirely from renewable castor oil,” said Adrien Lapeyre, global 3D printing market manager for Arkema’s high-performance polymers.”

“We are glad that we could support HEXR and EOS with our Digital Enterprise portfolio,” explains Dr. Karsten Heuser, Vice President Additive Manufacturing at Siemens Digital Industries. “With the help of our end-to-end solutions, we created a digital twin of an industrialized AM factory and helped to optimize the design and streamline production processes—even before production started. By combining simulations, design optimization, and production scenarios with a high degree of automation, we were able to predict and reduce cost per part significantly—enabling HEXR to scale their application into mass production.”


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