At Prototal, we help brands push the boundaries of design and manufacturing. Working with Hexr, we combined our expertise in polymer Industrial 3D Printing with 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 outperforms traditional designs, is lightweight, and maximises safety for cyclists worldwide. Using industrially 3D-printed honeycomb structures, our team helped translate Hexr’s concept into a fully functional product, optimising both ergonomics and material efficiency.
From Concept to Market at Lightning Speed
Prototal’s collaborative approach accelerated Hexr’s development process. From CAD design optimisation to prototype testing and final production, our team ensured Hexr could bring their helmet to market quickly without compromising quality.
We leveraged Polyamide PA11, a high-performance material known for its impact resistance, elasticity, and ability to form thin lattice structures, enabling Hexr to deliver a helmet that is both safe and lightweight.
Expert Collaboration for Superior Results
Working closely with Hexr, Prototal provided:
- Design optimisation for Industrial 3D Printing
- Material selection and testing for safety and performance
- Rapid prototyping and iteration to reduce time-to-market
- Sustainable, high-quality production solutions
“Prototal’s 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’s both safe and lightweight,” says James Cook, Hexr CEO and Founder.
Why 3D Printing Matters
Traditional helmet manufacturing often relies on mass-produced, fossil-based materials like EPS. Through 3D printing, Prototal helped Hexr avoid high start-up costs, reduce waste, and produce customised helmets on demand, supporting both performance and sustainability goals.
The Result: A Next-Level Cycling Helmet
Together with Hexr, Prototal helped develop a helmet that:
- Offers enhanced safety with optimised honeycomb structures
- Maintains lightweight comfort for long rides
- Uses high-performance, sustainable materials
- Allows customised, on-demand production
- Reduces environmental impact compared to traditional manufacturing
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 to cyclists around the world.
