{"id":9276,"date":"2026-01-08T13:48:53","date_gmt":"2026-01-08T12:48:53","guid":{"rendered":"https:\/\/prototalgroup.com\/cases\/innovative-3d-printed-bicycle-helmets\/"},"modified":"2026-09-19T04:57:39","modified_gmt":"2026-09-19T02:57:39","slug":"hexr","status":"publish","type":"case_studies","link":"https:\/\/prototalgroup.com\/uk\/cases\/hexr\/","title":{"rendered":"Innovative 3D-Printed Bicycle Helmets"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\">At Prototal, we help brands push the boundaries of design and manufacturing<strong>.<\/strong> Working with <a href=\"https:\/\/hexr.com\">Hexr<\/a>, we combined our expertise in polymer Industrial 3D Printing with 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 class=\"wp-block-paragraph\">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:\/\/prototalgroup.com\/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 class=\"wp-block-paragraph\">Prototal\u2019s collaborative approach accelerated Hexr\u2019s 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. <\/p>\n\n<p class=\"wp-block-paragraph\">We leveraged\u00a0<a href=\"https:\/\/prototalgroup.com\/?page_id=4715\">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 class=\"wp-block-paragraph\">Working closely with Hexr, Prototal provided:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Design optimisation for Industrial 3D Printing<\/li>\n\n\n\n<li>Material selection and testing for safety and performance<\/li>\n\n\n\n<li><a href=\"https:\/\/prototalgroup.com\/solutions\/rapid-prototyping\/\">Rapid prototyping<\/a> and iteration\u00a0to reduce time-to-market<\/li>\n\n\n\n<li>Sustainable, high-quality production solutions<\/li>\n<\/ul>\n\n<blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\">\n<p class=\"wp-block-paragraph\">\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 class=\"wp-block-paragraph\">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. <\/p>\n\n<h2 class=\"wp-block-heading\">The Result: A Next-Level Cycling Helmet<\/h2>\n\n<p class=\"wp-block-paragraph\">Together with Hexr, Prototal helped develop a helmet that:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Offers enhanced safety with optimised honeycomb structures<\/li>\n\n\n\n<li>Maintains lightweight comfort for long rides<\/li>\n\n\n\n<li>Uses high-performance, sustainable materials<\/li>\n\n\n\n<li>Allows customised, on-demand production<\/li>\n\n\n\n<li>Reduces environmental impact compared to traditional manufacturing<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n<p class=\"wp-block-paragraph\">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.<\/p>\n\n<p class=\"wp-block-paragraph\"><\/p>\n","protected":false},"excerpt":{"rendered":"<p>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\u00a0outperforms traditional designs, is\u00a0lightweight, and\u00a0maximizes [&hellip;]<\/p>\n","protected":false},"author":3,"featured_media":9277,"comment_status":"open","ping_status":"closed","template":"","categories":[207],"class_list":["post-9276","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 v28.2 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Innovative 3D-Printed Bicycle Helmets | 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:\/\/prototalgroup.com\/uk\/cases\/hexr\/\" \/>\n<meta property=\"og:locale\" content=\"en_GB\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Innovative 3D-Printed Bicycle Helmets | Prototal\" \/>\n<meta property=\"og:description\" content=\"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\u00a0outperforms traditional designs, is\u00a0lightweight, and\u00a0maximizes [&hellip;]\" \/>\n<meta property=\"og:url\" content=\"https:\/\/prototalgroup.com\/uk\/cases\/hexr\/\" \/>\n<meta property=\"og:site_name\" content=\"Prototal\" \/>\n<meta property=\"article:modified_time\" content=\"2026-09-19T02:57:39+00:00\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Estimated reading time\" \/>\n\t<meta name=\"twitter:data1\" content=\"2 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\n\t    \"@context\": \"https:\\\/\\\/schema.org\",\n\t    \"@graph\": [\n\t        {\n\t            \"@type\": \"WebPage\",\n\t            \"@id\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/cases\\\/hexr\\\/\",\n\t            \"url\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/cases\\\/hexr\\\/\",\n\t            \"name\": \"Innovative 3D-Printed Bicycle Helmets | Prototal\",\n\t            \"isPartOf\": {\n\t                \"@id\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/#website\"\n\t            },\n\t            \"primaryImageOfPage\": {\n\t                \"@id\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/cases\\\/hexr\\\/#primaryimage\"\n\t            },\n\t            \"image\": {\n\t                \"@id\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/cases\\\/hexr\\\/#primaryimage\"\n\t            },\n\t            \"thumbnailUrl\": \"https:\\\/\\\/prototalgroup.com\\\/app\\\/uploads\\\/2026\\\/01\\\/hexr-1-png.avif\",\n\t            \"datePublished\": \"2026-01-08T12:48:53+00:00\",\n\t            \"dateModified\": \"2026-09-19T02:57:39+00:00\",\n\t            \"breadcrumb\": {\n\t                \"@id\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/cases\\\/hexr\\\/#breadcrumb\"\n\t            },\n\t            \"inLanguage\": \"en-GB\",\n\t            \"potentialAction\": [\n\t                {\n\t                    \"@type\": \"ReadAction\",\n\t                    \"target\": [\n\t                        \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/cases\\\/hexr\\\/\"\n\t                    ]\n\t                }\n\t            ]\n\t        },\n\t        {\n\t            \"@type\": \"ImageObject\",\n\t            \"inLanguage\": \"en-GB\",\n\t            \"@id\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/cases\\\/hexr\\\/#primaryimage\",\n\t            \"url\": \"https:\\\/\\\/prototalgroup.com\\\/app\\\/uploads\\\/2026\\\/01\\\/hexr-1-png.avif\",\n\t            \"contentUrl\": \"https:\\\/\\\/prototalgroup.com\\\/app\\\/uploads\\\/2026\\\/01\\\/hexr-1-png.avif\",\n\t            \"width\": 2048,\n\t            \"height\": 1371\n\t        },\n\t        {\n\t            \"@type\": \"BreadcrumbList\",\n\t            \"@id\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/cases\\\/hexr\\\/#breadcrumb\",\n\t            \"itemListElement\": [\n\t                {\n\t                    \"@type\": \"ListItem\",\n\t                    \"position\": 1,\n\t                    \"name\": \"Home\",\n\t                    \"item\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/\"\n\t                },\n\t                {\n\t                    \"@type\": \"ListItem\",\n\t                    \"position\": 2,\n\t                    \"name\": \"Case Studies\",\n\t                    \"item\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/cases\\\/\"\n\t                },\n\t                {\n\t                    \"@type\": \"ListItem\",\n\t                    \"position\": 3,\n\t                    \"name\": \"Innovative 3D-Printed Bicycle Helmets\"\n\t                }\n\t            ]\n\t        },\n\t        {\n\t            \"@type\": \"WebSite\",\n\t            \"@id\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/#website\",\n\t            \"url\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/\",\n\t            \"name\": \"Prototal\",\n\t            \"description\": \"From one to one million\",\n\t            \"publisher\": {\n\t                \"@id\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/#organization\"\n\t            },\n\t            \"potentialAction\": [\n\t                {\n\t                    \"@type\": \"SearchAction\",\n\t                    \"target\": {\n\t                        \"@type\": \"EntryPoint\",\n\t                        \"urlTemplate\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/?s={search_term_string}\"\n\t                    },\n\t                    \"query-input\": {\n\t                        \"@type\": \"PropertyValueSpecification\",\n\t                        \"valueRequired\": true,\n\t                        \"valueName\": \"search_term_string\"\n\t                    }\n\t                }\n\t            ],\n\t            \"inLanguage\": \"en-GB\"\n\t        },\n\t        {\n\t            \"@type\": \"Organization\",\n\t            \"@id\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/#organization\",\n\t            \"name\": \"Prototal\",\n\t            \"url\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/\",\n\t            \"logo\": {\n\t                \"@type\": \"ImageObject\",\n\t                \"inLanguage\": \"en-GB\",\n\t                \"@id\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/#\\\/schema\\\/logo\\\/image\\\/\",\n\t                \"url\": \"https:\\\/\\\/prototalgroup.com\\\/app\\\/uploads\\\/2026\\\/03\\\/yoast-seo-default-logo.avif\",\n\t                \"contentUrl\": \"https:\\\/\\\/prototalgroup.com\\\/app\\\/uploads\\\/2026\\\/03\\\/yoast-seo-default-logo.avif\",\n\t                \"width\": 696,\n\t                \"height\": 696,\n\t                \"caption\": \"Prototal\"\n\t            },\n\t            \"image\": {\n\t                \"@id\": \"https:\\\/\\\/prototalgroup.com\\\/uk\\\/#\\\/schema\\\/logo\\\/image\\\/\"\n\t            }\n\t        }\n\t    ]\n\t}<\/script>\n<!-- \/ Yoast SEO plugin. -->","yoast_head_json":{"title":"Innovative 3D-Printed Bicycle Helmets | Prototal","robots":{"index":"index","follow":"follow","max-snippet":"max-snippet:-1","max-image-preview":"max-image-preview:large","max-video-preview":"max-video-preview:-1"},"canonical":"https:\/\/prototalgroup.com\/uk\/cases\/hexr\/","og_locale":"en_GB","og_type":"article","og_title":"Innovative 3D-Printed Bicycle Helmets | Prototal","og_description":"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\u00a0outperforms traditional designs, is\u00a0lightweight, and\u00a0maximizes [&hellip;]","og_url":"https:\/\/prototalgroup.com\/uk\/cases\/hexr\/","og_site_name":"Prototal","article_modified_time":"2026-09-19T02:57:39+00:00","twitter_card":"summary_large_image","twitter_misc":{"Estimated reading time":"2 minutes"},"schema":{"@context":"https:\/\/schema.org","@graph":[{"@type":"WebPage","@id":"https:\/\/prototalgroup.com\/uk\/cases\/hexr\/","url":"https:\/\/prototalgroup.com\/uk\/cases\/hexr\/","name":"Innovative 3D-Printed Bicycle Helmets | Prototal","isPartOf":{"@id":"https:\/\/prototalgroup.com\/uk\/#website"},"primaryImageOfPage":{"@id":"https:\/\/prototalgroup.com\/uk\/cases\/hexr\/#primaryimage"},"image":{"@id":"https:\/\/prototalgroup.com\/uk\/cases\/hexr\/#primaryimage"},"thumbnailUrl":"https:\/\/prototalgroup.com\/app\/uploads\/2026\/01\/hexr-1-png.avif","datePublished":"2026-01-08T12:48:53+00:00","dateModified":"2026-09-19T02:57:39+00:00","breadcrumb":{"@id":"https:\/\/prototalgroup.com\/uk\/cases\/hexr\/#breadcrumb"},"inLanguage":"en-GB","potentialAction":[{"@type":"ReadAction","target":["https:\/\/prototalgroup.com\/uk\/cases\/hexr\/"]}]},{"@type":"ImageObject","inLanguage":"en-GB","@id":"https:\/\/prototalgroup.com\/uk\/cases\/hexr\/#primaryimage","url":"https:\/\/prototalgroup.com\/app\/uploads\/2026\/01\/hexr-1-png.avif","contentUrl":"https:\/\/prototalgroup.com\/app\/uploads\/2026\/01\/hexr-1-png.avif","width":2048,"height":1371},{"@type":"BreadcrumbList","@id":"https:\/\/prototalgroup.com\/uk\/cases\/hexr\/#breadcrumb","itemListElement":[{"@type":"ListItem","position":1,"name":"Home","item":"https:\/\/prototalgroup.com\/uk\/"},{"@type":"ListItem","position":2,"name":"Case Studies","item":"https:\/\/prototalgroup.com\/uk\/cases\/"},{"@type":"ListItem","position":3,"name":"Innovative 3D-Printed Bicycle Helmets"}]},{"@type":"WebSite","@id":"https:\/\/prototalgroup.com\/uk\/#website","url":"https:\/\/prototalgroup.com\/uk\/","name":"Prototal","description":"From one to one million","publisher":{"@id":"https:\/\/prototalgroup.com\/uk\/#organization"},"potentialAction":[{"@type":"SearchAction","target":{"@type":"EntryPoint","urlTemplate":"https:\/\/prototalgroup.com\/uk\/?s={search_term_string}"},"query-input":{"@type":"PropertyValueSpecification","valueRequired":true,"valueName":"search_term_string"}}],"inLanguage":"en-GB"},{"@type":"Organization","@id":"https:\/\/prototalgroup.com\/uk\/#organization","name":"Prototal","url":"https:\/\/prototalgroup.com\/uk\/","logo":{"@type":"ImageObject","inLanguage":"en-GB","@id":"https:\/\/prototalgroup.com\/uk\/#\/schema\/logo\/image\/","url":"https:\/\/prototalgroup.com\/app\/uploads\/2026\/03\/yoast-seo-default-logo.avif","contentUrl":"https:\/\/prototalgroup.com\/app\/uploads\/2026\/03\/yoast-seo-default-logo.avif","width":696,"height":696,"caption":"Prototal"},"image":{"@id":"https:\/\/prototalgroup.com\/uk\/#\/schema\/logo\/image\/"}}]}},"_links":{"self":[{"href":"https:\/\/prototalgroup.com\/uk\/wp-json\/wp\/v2\/case_studies\/9276","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/prototalgroup.com\/uk\/wp-json\/wp\/v2\/case_studies"}],"about":[{"href":"https:\/\/prototalgroup.com\/uk\/wp-json\/wp\/v2\/types\/case_studies"}],"author":[{"embeddable":true,"href":"https:\/\/prototalgroup.com\/uk\/wp-json\/wp\/v2\/users\/3"}],"replies":[{"embeddable":true,"href":"https:\/\/prototalgroup.com\/uk\/wp-json\/wp\/v2\/comments?post=9276"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/prototalgroup.com\/uk\/wp-json\/wp\/v2\/media\/9277"}],"wp:attachment":[{"href":"https:\/\/prototalgroup.com\/uk\/wp-json\/wp\/v2\/media?parent=9276"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/prototalgroup.com\/uk\/wp-json\/wp\/v2\/categories?post=9276"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}