Case Study - Sports Protective Equipment


30% Lighter. PAM 3D-Printed NFL Helmet Components with RHEON™ P3D 001.

Pollen AM and RHEON Labs qualified a strain-rate sensitive impact material for pellet 3D printing (PAM) and benchmarked it against injection moulding on real protective components retrofitted into the Xenith Shadow XR helmet.

Xenith Shadow XR helmet retrofitted with PAM 3D-printed protective components

Xenith Shadow XR helmet retrofitted with printed protective components (visible under the shell). Credit: RHEON Labs.

Injection-moulded protective components lock manufacturers into expensive tooling and fixed internal geometry. This case study shows what changes when the same material is printed instead with PAM, starting with a 30% weight reduction at equal or better impact-damping performance.

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  • The full weight and impact-energy benchmark: PAM 3D-printed vs injection moulded, at low and high impact speed
  • RHEON™ P3D 001 material properties and qualified Pam Pro printing parameters
  • Behind-the-scenes photos of the Pam Pro process





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See the complete benchmark data, material specs and process details.