{"id":192992,"date":"2023-03-20T00:00:00","date_gmt":"2023-03-20T00:00:00","guid":{"rendered":"https:\/\/facfox.com\/news\/kav-sports-and-jabil-create-the-perfect-personalized-bicycle-helmet-consumer-products\/"},"modified":"2023-03-20T00:00:00","modified_gmt":"2023-03-20T00:00:00","slug":"kav-sports-and-jabil-create-the-perfect-personalized-bicycle-helmet-consumer-products","status":"publish","type":"post","link":"https:\/\/facfox.com\/news\/kav-sports-and-jabil-create-the-perfect-personalized-bicycle-helmet-consumer-products\/","title":{"rendered":"KAV Sports and Jabil create the perfect personalized bicycle helmet Consumer Products"},"content":{"rendered":"

Jabil Inc. has teamed with KAV Sports to create made-to-order, personalized bicycle helmets that deliver superior comfort and protection using custom-engineered materials and additive manufacturing. Recognized by Time Magazine as one of the \u2018best inventions of 2022\u2019, the KAV Portola helmet is made from custom nylon carbon-fiber material \u2013 engineered by Jabil \u2013 to meet exacting standards for performance and aesthetics.<\/p>\n

\u201cTo fulfill our mission of saving lives, we needed to produce a better-fitting helmet that people would want to wear,\u201d said Whitman Kwok, Founder, and CEO of KAV Sports. \u201cFor consumer<\/a>s to experience the benefits of customization, we had to overcome limitations in materials and manufacturing. Jabil knocked it out of the park by engineering a custom material that met stringent criteria and could be manufactured using 3D printing<\/a> to create something really unique and special for the helmet industry.\u201d<\/p>\n

The perfect fit<\/h2>\n

KAV\u2019s Portola helmet. <\/p>\n

Traditional bike helmets are made from injection-molded, expanded polystyrene (EPS) foam and come in one to three sizes \u2013 which fall short in accommodating various head sizes and shapes. Typical helmets also have limitations in stability, durability, and comfort.<\/p>\n

While KAV wanted a novel material that was as light as EPS, the company sought superior performance in temperatures ranging from -15 degrees to over 60 degrees Celsius. KAV engineers evaluated more than 20 off-the-shelf materials \u2013 all of which failed to meet the company\u2019s criteria for absorbing high-velocity impacts or providing sufficient stability under extreme environment<\/a>al conditions.<\/p>\n

KAV enlisted the help of Jabil to create a custom material that was stiff and strong, yet flexible enough to accommodate both high and low temperatures. In addition to providing excellent energy<\/a> absorption, the material needed to increase layer-to-layer adhesion for consistent performance, as well as improved look-and-feel. A team of additive manufacturing engineers, chemists, materials scientists, and production experts at Jabil\u2019s Materials Innovation Center, in Minnesota, created a completely new and customized material \u2013 in just nine months \u2013 that met all KAV\u2019s expectations.<\/p>\n

Prioritizing polymer science<\/h2>\n

KAV\u2019s Portola helmet. <\/p>\n

To achieve that milestone, Jabil applied comprehensive innovations in materials formulation, compound development, materials systems integration, and ISO 9001 Quality Management System certification. \u201cWe take a polymer science approach to developing additive materials,\u201d said Matt Torosian, director of product management for additive manufacturing at Jabil. \u201cJabil engineers materials that work with additive manufacturing processes in a repeatable manner to meet customer requirements and manufacture top-quality products.\u201d<\/p>\n

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Jabil and KAV Sports developed and tested nearly 30 iterations of custom polymer formulations and compounds before creating the proprietary nylon carbon-fiber composite that embodied all the necessary properties. Jabil\u2019s extensive expertise and experience in materials processing, testing, and scaling proved instrumental in formulating the polymer \u2013 compounding the final filament and attaining ISO 9001 Quality Management System certification.<\/p>\n

KAV then completed the necessary validation testing to achieve certification in accordance with the US Consumer Product Safety Commission (CPSC). When KAV launched the Portola helmet featuring the new material in April 2022, the company asserted that the product not only met, but exceeded, US CPSC safety standards for impact resistance by more than 25%.<\/p>\n

Improving customer experiences<\/h2>\n

KAV\u2019s custom material is available in grey, black, and white colors, and the use of 3D printing<\/a> enables the two-to-three-week delivery of the made-to-order helmets. Production of these unique, energy<\/a>-absorbing structures would not be possible via traditional manufacturing. Additive manufacturing also allows KAV Sports to reduce production costs and unnecessary waste.<\/p>\n

Thanks to its collaboration with Jabil, KAV is planning to expand its product portfolio and market reach by leveraging Jabil\u2019s additive manufacturing prowess, global additive manufacturing capacity, and extensive supply chain capabilities.<\/p>\n

\u201cWe have big ambitions. There\u2019s no reason we can\u2019t bring mass customization and a bespoke experience for protective gear across sports. So, we\u2019re going to keep working with Jabil as our esteemed provider to perform that optimization as we continue to grow,\u201d said David Stoutamire, CTO and co-founder of KAV Sports.<\/p>\n

More on the KAV and Jabil case study can be found here.<\/p>\n

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You might also like:<\/h5>\n

Optomec mourns the loss of CEO, Dave Ramahi: <\/a>Dave Ramahi joined Optomec in 2002 after successful leadership positions in the computer graphics industry.\u00a0 Under Dave\u2019s leadership as CEO, Optomec transitioned from start-up mode to sustained growth, to profitability, to ultimately achieving Dave\u2019s vision of becoming one of the few additive manufacturing companies that derives the majority of its revenue from production applications. Dave received his BS in Mechanical Engineering from the Massachusetts Institute of Technology (MIT).<\/p><\/blockquote>\n

* This article is reprinted from 3D Printing Media Network<\/a>. If you are involved in infringement, please contact us to delete it.<\/p>\n

<\/i> Author: Edward Wakefield<\/p>\n","protected":false},"excerpt":{"rendered":"

Jabil Inc. has teamed with KAV Sports to create made-to-order, personalized bicycle helmets that deliver superior comfort and protection using custom-engineered materials and additive manufacturing. Recognized by Time Magazine as one of the \u2018best inventions of 2022\u2019, the KAV Portola helmet is made from custom nylon carbon-fiber material \u2013 engineered by Jabil \u2013 to meet exacting standards for performance and aesthetics.<\/p>\n","protected":false},"author":3,"featured_media":192994,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"fifu_image_url":"\/news\/wp-content\/uploads\/2023\/05\/8102454759670764376.jpeg","fifu_image_alt":"","footnotes":""},"categories":[285],"tags":[4046,5086],"class_list":["post-192992","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-business","tag-acquisitions","tag-mergers-partnershipsconsumer-productssports-equipment"],"yoast_head":"\nKAV Sports and Jabil create the perfect personalized bicycle helmet Consumer Products - FacFox News<\/title>\n<meta name=\"description\" content=\"Jabil Inc. has teamed with KAV Sports to create made-to-order, personalized bicycle helmets that deliver superior comfort and protection using custom-engineered materials and additive manufacturing. 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