nFrontier envisioned one of the safest, smartest bicycle helmets.
An airbag around the face activates in the case of an accident. LED lights on the back of the helmet help cyclists safely signal. A LIDAR (light detection and ranging) safety system warns cyclists of potential dangers in blind spots.
To turn that vision into a reality, nFrontier partnered with MakerVerse to 3D print a prototype of the PYLO helmet.
The outher shell of the helmet was primed and painted.
The inner frame was also made using SLS 3D printing technology.
Co-founder and CFO of nFrontier
nFrontier felt the urgent need to enhance safety for cyclists, whether recreational riders or athletes. The team rigorously designed the helmet, which brought together technologies from the automotive, electronic, and computer industries.
For nFrontier, a high-quality prototype was critically important. The prototype would be brought to trade shows, shown to media outlets, and used to attract future investment.
Therefore, the prototype must be expertly manufactured, visually striking, and lightweight.
The 3D-printed inner shell is lightweight.
To achieve a prototype highlighting everything the PYLO helmet offers, nFrontier put their trust in MakerVerse.
Before production began, nFrontier worked with MakerVerse’s expert engineering team to determine the best way to produce the parts.
Based on the project needs, MakerVerse recommended using Selective Laser Sintering, an additive manufacturing technology capable of complex, highly accurate polymer parts. The material used was PA 12, a polyamide with high strength and long-term stability.
Thanks to MakerVerse’s fully-vetted supply chain, the perfect manufacturer produced the parts, including the outer shell and intricate inner lining.
With the 3D-printed parts provided by MakerVerse, nFrontier was ready to show off the PYLO prototype to the world.
nFrontier unveiled the helmet at the IAA Mobility 2023 motor show in Germany, generating a strong positive reaction from attendees and the media. Attendees especially noted the unique technologies and impressive design of the helmet.
With the prototype completed, nFrontier looks forward to bringing the product to market to make cycling safer.
“MakerVerse helped make the prototyping process easy for us,” said Stephan Beyer, co-founder of nFrontier. “The team did a great job, from the initial planning to the quality control.”
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