Preview Mode Links will not work in preview mode

Welcome to the Pod!  Our feed is available on all major podcast platforms and is supported by a small number of advertisers and directly by people like you.   If you've made it this far, please consider subscribing to the podcast and if you like what I'm doing, please consider supporting financially via the link below. 

Support the Podcast: Buy Me a Coffee

  1. All Episodes
  2. Beyond Aero: How KAV is Reinventing the Bike Helmet from the Inside Out

Beyond Aero: How KAV is Reinventing the Bike Helmet from the Inside Out

Jun 10, 2025

Craig welcomes back Whitman Kwok, founder of KAV Helmets, to talk about the launch of their latest high-performance helmet, the Rhoan. They dive into the evolution of 3D-printed custom helmet technology, the bold move to open a new U.S.-based manufacturing facility in Buffalo, and how pro rider feedback helped shape the future of bike safety and performance. From tech talk to trail stories, this episode is a must-listen for gearheads and gravel cyclists alike.

keywordsKAV Helmets, 3D printing, custom helmets, helmet technology, cycling safety, helmet design, manufacturing, aerodynamics, crash replacement, cycling gear
summaryIn this conversation, Craig Dalton speaks with Whitman Kwok, founder and CEO of KAV Helmets, about the evolution of the KAV brand, the innovative technology behind their custom 3D-printed helmets, and the recent launch of the Rhoan helmet. They discuss the challenges and successes of expanding manufacturing operations to Buffalo, the importance of aerodynamics and ventilation in helmet design, and the rigorous testing and safety standards that KAV Helmets adheres to. Whitman shares insights into the company's mission to provide confidence and safety for cyclists, as well as their unique crash replacement policy.
takeaways
  • KAV Helmets custom makes helmets using 3D printing technology.
  • The process involves taking a single photo to create a custom fit.
  • 3D printing allows for innovative designs not possible with traditional methods.
  • KAV expanded its manufacturing to Buffalo for better efficiency.
  • The Rhoan helmet was designed for both aerodynamics and ventilation.
  • Testing involved extensive wind tunnel analysis for validation.
  • KAV Helmets has a one-time crash replacement policy for safety.
  • The company adheres to high safety standards beyond regulatory requirements.
  • KAV Helmets aims to provide confidence in cycling activities.
  • The customization options allow users to express their creativity.
titles
  • Revolutionizing Cycling Safety with KAV Helmets
  • The Future of Custom Helmets: KAV's Journey
 
Chapters
00:00Introduction and Background of Kav Helmets
02:00Custom 3D Printing Technology
04:19Advantages of 3D Printing in Helmet Design
08:17Expansion and Manufacturing Journey
13:22New Manufacturing Facility in Buffalo
16:40Launch of the New Rhoan Helmet
18:22Innovative Design Features of the Rhone Helmet
22:32Innovative Helmet Design and Air Fit Suspension
24:58Aerodynamics and Wind Tunnel Testing
26:59Balancing Aesthetics and Performance
30:45Customization and User Experience
33:00Collaboration with Professional Athletes
34:38Crash Replacement Policy and Safety Standards
36:05Testing Standards and Internal Validation
40:10In-House Testing and Product Development
42:18The Evolution of Helmet Design and Safety Features
42:38New Chapter