Tech Tuesday #1 - Composite Fusion

On this first edition of Tech Tuesday, we are covering the innovation that was the foundation behind Kali's inception. Our core technology, COMPOSITE FUSION, was the result over 3 years of R&D and tooling, well before we even produced our first helmet. It is the DNA found in all our helmets - it allows us to make them smaller yet lighter and stronger.
COMPOSITE FUSION
COMPOSITE FUSION (CF) is Kali Protectives' proprietary in-molding technology that bonds the helmet shell and foam together. This is our number one advantage over the competition.
In an impact, the bonded shell and foam liner work together as a system, dissipating the energy of impact more effectively than  construction.
  • BENEFITS:
    • 25% thinner outer shell can be used - breaks down faster dissipating impact energy into foam liner faster.
    • 15-25% softer foam can be used - softer cushion next to your head. 
    • Increased dynamic range - better energy management allowing Kali helmets to address a wider range of impacts forces.
    • Thinner shell + softer foam + in-molding = smaller, lighter, stronger helmets.

IMPACT TESTING
Traditional vs. Composite Fusion

Traditional Construction (Grey Line)

  • Helmet shell and foam liner are molded separately and are then glued or taped together during assembly.
  • The imperfect shape of the shell and foam liner creates an air gap between them.
  • A thicker shell and harder foam liner are needed to pass testing standards.
  • Heavier helmet overall.
  • RESULT:
    • Double impact curve - shell and foam dissipate impact energy separately resulting in a double spike of g-forces transferred to the head. 
    • Increased head trauma in a crash (big spikes).

Kali's Composite Fusion (Yellow Line)

  • Helmet shell and foam liner are bonded together through in-molding, eliminating the air gap.
  • RESULT:
    • Eliminates double impact curve - shell and foam work together as a system to dissipate impact energy more efficiently.
    • Reduced head trauma in a crash (mellow curve).

WHY KALI?

  • From mundane to insane - Kali helmets use advanced materials designed to address a wider range of impacts.
  • Smaller, Lighter, Stronger - we make helmets as small (low volume) and light (lower mass) as possible to reduce rotational acceleration of the head during impact.
  • Our mission - to deliver the absolute best available protection to riders today.