Pollen AM and RHEON Labs have qualified the RHEON™ P3D 001 cushioning material on the Pam Pro pellet 3D printer, achieving a thirty percent weight reduction in protective components integrated into an NFL football helmet compared to injection-molded counterparts.
Molds Cost Less and Lattice Structures Improve Design Flexibility
- Equipment Valuation: The elimination of high-cost tooling molds valued up to €150,000 alters procurement economics for athletic protection manufacturers.
- Design Flexibility: Customizable lattice structures allow brands to tune impact response zone-by-zone for specific positional demands.
- Deployment Timeline: Upcoming live webinars and industry showcases, including Formnext 2026, will be used to present results.
The Injection Molding Bottleneck
Traditional football helmet manufacturing relies heavily on injection molding for protective internal components. A typical production lot ranges from 5,000 to 10,000 units, with each helmet containing between one and twelve protective pieces. While suitable for volume, this traditional workflow demands substantial upfront capital before a single component takes physical form. Tooling expenses can reach up to €150,000, and lead times frequently extend to three months.
Standard molds impose strict geometric constraints on engineers. Production requires specific draft angles, uniform wall thicknesses, and minimal undercuts. These physical limitations make it exceptionally difficult to produce internal lattice structures or vary mechanical properties within a single component. Additive manufacturing bypasses these restrictions entirely.
| Metric | Injection-Molded Standard | Pollen AM x RHEON 3D Printed |
|---|---|---|
| Tooling Investment | Up to €150,000 | Eliminated |
| Lead Times | Up to three months | Accelerated via digital file |
| Impact Tuning | Uniform across part | Variable zone-by-zone density |
Material Dynamics of RHEON™ P3D 001
The newly qualified RHEON™ P3D 001 material responds dynamically to strain rates. Its rigidity shifts depending on how rapidly the material deforms during an impact event. The component stays soft and flexible during normal wear, then stiffens instantly upon receiving an impact to absorb energy. This protective behavior is intrinsic to the material itself, requiring no post-treatment or secondary manufacturing processes.
The raw polymer arrives as pellets, matching the exact feedstock utilized in standard injection molding. This keeps raw material costs comparable while eradicating upfront mold expenses. Using the Pam Pro printer, the development team modified lattice density, cell shapes, and wall thicknesses across different regions of the helmet. Adapting these print parameters represents a core technical milestone for Pollen AM and RHEON Labs.
3D-Printed Components Match or Exceed Injection-Molded Damping Performance
RHEON Labs tested the 3D-printed components against injection-molded parts of identical geometry. The laboratory evaluated transmitted energy across both low-energy and high-energy impacts. Despite shedding thirty percent of the weight, the printed parts delivered damping performance at least equal to injection-molded versions, and outperformed them under specific impact conditions.
Victor Roux, co-founder and president of Pollen AM, stated: Sport is one of the environments most demanding for a material: the components must protect, flex and remain light, and the brands want them quicker.
He added that the collaboration proves what happens when an open pellet-based process meets advanced polymer engineering.
Dr. Sarah Karmel, CSO of RHEON Labs, remarked: This collaboration demonstrates how advanced materials and additive manufacturing can work in synergy to open up new possibilities for protective gear.
Expanding Beyond Football Protection
Following the integration trials inside the Xenith Shadow XR helmet, the partnership is targeting broader protective equipment sectors. Both companies intend to scale the pellet 3D printing approach into motorcycle gear, cycling equipment, and defense applications.
Pollen AM and RHEON Labs plan to showcase their complete findings during a live webinar on November 25, 2026, followed by a physical demonstration at Formnext 2026 in Frankfurt within Hall 12.1 at Stand A78.
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