Composite Fusion

In-molding technology merging the shell and EPS foam liner. Better impact energy management, increased dynamic range - smaller, lighter and stronger.

Why Kali?

Kali Protectives came from a significant breakthrough in helmet safety technology - Composite Fusion™, a process that bonds the helmet shell and EPS foam eliminating the air gap found in traditionally constructed helmets. Composite Fusion™ features a thinner outer shell that works in concert with the EPS foam to effectively reduce impact forces in a crash.

By manufacturing lighter and stronger helmets, we can significantly reduce linear and rotational impacts simply by placing less mass on your head, effectively giving your brain a few extra milliseconds of protection.

No safety technology exists that can completely prevent injury, but we can reduce the degree of trauma. The more we learn and the more we understand, the better protective gear we can provide. That is our mission - to deliver the absolute best protection available to riders today.

Composite Fusion Plus

While dozens of manufacturers in the powersport world utilize dual density foams, they are generally assembled like the layers of a cake. Our Composite Fusion™ Plus Technology uses a layer of multi density cone shaped foam that intersect with a layer of softer foam that surrounds the head. In an impact, these cones act as a progressive damper to absorb different levels of impact. As they collapse, these cones also direct energy sideways and away from the brain.



Note the air gap between the shell and the inner EPS foam in a traditional helmet - that’s what creates the grey double impact curve seen on the graph. The air gap has been proven to add to head trauma in a crash.

Current helmet safety standards are based on tests conducted over 50 years ago, well before our current knowledge of concussive, subconcussive and rotational impacts. To pass these standards, helmets constructed using traditional methods utilize hard shells and very stiff foam, compromising their ability to perform at low to medium speed impacts.

Composite Fusion™ eliminates the gap putting softer and more efficient material next to your head - exactly where you need it.

LDL - Low Density Layer

The Low Density Layer (LDL) consists of specially designed viscoelastic padding placed throughout the interior of the helmet. It reduces rotational impact forces by up to 25% and low-G linear impact forces by up to 30%. Introduced in 2012 as Bumper Fit, this first generation of LDL consists of a specially designed vinyl nitrile padding system that lined the interior of the helmet. This yellow or black padding reduces low-G linear impacts while also improving helmet fit.

Composite Fusion 3

We're constantly testing new technology and after experimenting with dozens of different geometric shapes, we found a pyramid shaped that was better at dissipating forces than the our existing conehead technology in certain applications. Like Composite Fusion™ Plus, this tetrahedral layer of multi density EPS foam is able to act as a progressive damper to absorb different levels of impacts, as well as help distribute energy laterally, but it also allows us to create a smaller and lighter helmet.

Composite Fusion Squared

Combines multi-density EPS foam and dual direction geometric cone shapes. Interior and exterior impact energy management.

Nano Fusion

In-molded multi-density EPS with acrylic self-healing foam and carbon nanotubes. Dissipates impact energy more efficiently in a smaller volume.