Backed by EOS, Arkema and Siemens, HEXR opts for production of custom-made 3D Printed cycling helmets

London-based producer of custom-made cycling helmets, HEXR has called for the expertise of EOS in the production of its tailor-made 3D Printed cycling helmets.

Thanks to a new HEXR fitting app, the London-based company can deliver a complete scan-to-product-solution for high quality, safe 3D-printed cycling helmets. Furthermore, with the app-based head scan, users around the world can begin the creation of their helmet at home.

Siemens and Arkema that specialize in software technologies and materials, took part in the production process. Both companies bring their expertise to HEXR’s Integrated Scan-to-Print Solution.

Thanks to their digital enterprise portfolio, Siemens 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”, explains Dr. Karsten Heuser, Vice President Additive Manufacturing at Siemens Digital Industries.

Arkema comes into play with its high-performance polyamide 11 polymers, made up of renewable castor oil. According to Adrien Lapeyre, global 3D printing market manager for Arkema’s high performance polymers, this advanced material provides superior impact and lightweight properties Its sustainable feedstock “does not compete with food, and does not cause deforestation. The beans take less than one year to grow, as opposed to perhaps a million years required for traditional fossil feedstock.”

The 100% plant-based polyamide material is compatible with EOS 3D Printing technology. After the printing process, it is dyed in black before final inspection for structural integrity and finish quality.

Lastly, 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).

Markus Glasser, Senior Vice President EMEA explains: “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.”

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.”

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Corporate communication and marketing expert by training at 3D Adept, Kety is currently leading the publication’s editorial and content activities. She has a unique gift for knowing how to grab an audience's attention on insights that matter – in this case, everything related to additive manufacturing. She believes that a wide range of innovations still have to be discovered about the technologies that shape the world of tomorrow and she has made it her objective at 3D ADEPT Media.