{"id":20163,"date":"2026-01-08T13:48:53","date_gmt":"2026-01-08T12:48:53","guid":{"rendered":"https:\/\/prototal.info\/cases\/hexr\/"},"modified":"2026-04-30T14:17:49","modified_gmt":"2026-04-30T12:17:49","slug":"hexr","status":"publish","type":"case_studies","link":"https:\/\/prototal.info\/ch\/cases\/hexr\/","title":{"rendered":"Innovative 3D gedruckte Fahrradhelme"},"content":{"rendered":"\n<p>At Prototal, we help brands push the boundaries of design and manufacturing<strong>.<\/strong>\u00a0Working with <a href=\"https:\/\/hexr.com\">Hexr<\/a>, we combined our expertise in\u00a0polymer Industrial 3D Printing\u00a0with advanced design engineering to develop high-performance, lightweight, and impact-resistant bicycle helmets<\/p>\n\n<h2 class=\"wp-block-heading\">Driving Innovation with 3D Printing<\/h2>\n\n<p>Hexr approached Prototal with a vision: create a helmet that\u00a0outperforms traditional designs, is\u00a0lightweight, and\u00a0maximizes safety\u00a0for cyclists worldwide. Using <a href=\"https:\/\/prototal.info\/services\/industrial-3d-printing\/\">industrially\u00a03D-printed<\/a> honeycomb structures, our team helped translate Hexr\u2019s concept into a fully functional product, optimizing both\u00a0ergonomics and material efficiency.<\/p>\n\n<h2 class=\"wp-block-heading\">From Concept to Market at Lightning Speed<\/h2>\n\n<p>Prototal\u2019s collaborative approach accelerated Hexr\u2019s development process. From\u00a0CAD design optimization\u00a0to\u00a0prototype testing and final production, our team ensured Hexr could bring their helmet to market quickly without compromising quality.<\/p>\n\n<p>We leveraged\u00a0<a href=\"https:\/\/prototal.info\/services\/industrial-3d-printing\/polymer\/mjf\/pa-11\/\">Polyamide PA11<\/a>, a high-performance material known for its\u00a0impact resistance, elasticity, and ability to form thin lattice structures, enabling Hexr to deliver a helmet that is both safe and lightweight.<\/p>\n\n<h2 class=\"wp-block-heading\">Expert Collaboration for Superior Results<\/h2>\n\n<p>Working closely with Hexr, Prototal provided:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Design optimization\u00a0for Industrial 3D Printing<\/li>\n\n\n\n<li>Material selection and testing\u00a0for safety and performance<\/li>\n\n\n\n<li><a href=\"https:\/\/prototal.info\/solutions\/rapid-prototyping\/\">Rapid prototyping<\/a> and iteration\u00a0to reduce time-to-market<\/li>\n\n\n\n<li>Sustainable, high-quality production\u00a0solutions<\/li>\n<\/ul>\n\n<blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\">\n<p>\u201cPrototal\u2019s expertise allowed us to bring our vision to life faster than we ever imagined. Their deep knowledge of additive manufacturing and material science was crucial to creating a helmet that\u2019s both safe and lightweight,\u201d says James Cook, Hexr CEO and Founder.<\/p>\n<\/blockquote>\n\n<h2 class=\"wp-block-heading\">Why 3D Printing Matters<\/h2>\n\n<p>Traditional helmet manufacturing often relies on mass-produced, fossil-based materials like EPS. Through 3D printing, Prototal helped Hexr\u00a0avoid high start-up costs, reduce waste, and produce\u00a0customized helmets on demand, supporting both performance and sustainability goals.<\/p>\n\n<h2 class=\"wp-block-heading\">The Result: A Next-Level Cycling Helmet<\/h2>\n\n<p>Together with Hexr, Prototal helped develop a helmet that:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Offers\u00a0enhanced safety\u00a0with optimized honeycomb structures<\/li>\n\n\n\n<li>Maintains\u00a0lightweight comfort\u00a0for long rides<\/li>\n\n\n\n<li>Uses\u00a0high-performance, sustainable materials<\/li>\n\n\n\n<li>Allows\u00a0customized, on-demand production<\/li>\n\n\n\n<li>Reduces\u00a0environmental impact\u00a0compared to traditional manufacturing<\/li>\n<\/ul>\n\n<p><\/p>\n\n<p>Prototal is proud to partner with innovators like Hexr, combining design expertise, Industrial 3D Printing knowledge, and rapid prototyping capabilities to bring market-leading, sustainable, and safe products\u00a0to cyclists around the world.<\/p>\n\n<p><\/p>\n","protected":false},"excerpt":{"rendered":"<p>At Prototal, we help brands push the boundaries of design and manufacturing.\u00a0Working with Hexr, we combined our expertise in\u00a0polymer Industrial 3D Printing\u00a0with advanced design engineering to develop high-performance, lightweight, and impact-resistant bicycle helmets Driving Innovation with 3D Printing Hexr approached Prototal with a vision: create a helmet that\u00a0outperforms traditional designs, is\u00a0lightweight, and\u00a0maximizes safety\u00a0for cyclists worldwide. [&hellip;]<\/p>\n","protected":false},"author":3,"featured_media":20164,"comment_status":"open","ping_status":"closed","template":"","categories":[95],"class_list":["post-20163","case_studies","type-case_studies","status-publish","has-post-thumbnail","hentry","category-industrial-3d-printing"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.5 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Innovative 3D gedruckte Fahrradhelme | Prototal<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/prototal.info\/ch\/cases\/hexr\/\" \/>\n<meta property=\"og:locale\" content=\"de_DE\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Innovative 3D gedruckte Fahrradhelme | Prototal\" \/>\n<meta property=\"og:description\" content=\"At Prototal, we help brands push the boundaries of design and manufacturing.\u00a0Working with Hexr, we combined our expertise in\u00a0polymer Industrial 3D Printing\u00a0with advanced design engineering to develop high-performance, lightweight, and impact-resistant bicycle helmets Driving Innovation with 3D Printing Hexr approached Prototal with a vision: create a helmet that\u00a0outperforms traditional designs, is\u00a0lightweight, and\u00a0maximizes safety\u00a0for cyclists worldwide. 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