HEXR custom 3D printed helmet

HEXR began at University College London (UCL), where Co-Founder Jamie Cook, under the supervision of leading material scientist Prof Mark Miodownik started investigating cellular structures.

Every HEXR helmet is a one off 3D custom printed product, made to the precise dimensions and curvature of your head. It consists of two main parts, the inner honeycomb structure, and an outer shell.

You purchase your HEXR through their webstore. HEXR then sends you a fitting cap to capture your head measurements yourself at home, through their app.

The helmets are made from a plant-based material called Polyamide-11, made from 100% castor bean oil. This material is sourced sustainably by Arkema through the Pragati initiative, which supports sustainable farming practices, reducing water use, and fair treatment of workers.
The 3D printing is done by 3T Additive Manufacturing Ltd in Newbury. Using a technology known as Laser Sintering, the helmet is produced layer upon layer by using high-powered and ultra-fine lasers to melt portions of consecutive layers of powder with a thickness of 0.1mm. The regions that have been melted later cool and solidify, forming a solid structure, whereas the surrounding areas remain in powder form which can be brushed away. The entire process takes approximately 36 hours for a batch of 6 helmets.

HEXR claim that testing has shown a 8x better heat dissipation than traditional helmets, and also better injury prevention as compared to competing technologies such as MIPS.
A drawback is the increased weight (around 300g – 360g, depending on head size), and a higher than usual price.

Got feedback or questions? Please comment in the section below!