COMPOSITE FUSION

CAN'T CHANGE PHYSICS, BUT...

In the late 1600s, Sir Isaac Newton laid out a simple equation that changed physics forever.

Force = Mass x Acceleration

 When designing a helmet, we cannot change acceleration, but we can change the mass. Composite Fusion allows us to make smaller, lighter, and stronger helmets.

 

WHAT IS IT?

Composite Fusion is our proprietary in-molding technology that merges the shell and EPS foam liner together. It is the innovative helmet safety technology upon which Kali Protectives was founded in 2006. 

Today, it is a family of in-molding technologies that allow us to make helmets with better impact energy management and increased dynamic range.

 

WHY IS IT BETTER?

Composite Fusion eliminates the air gap between the shell and EPS foam liner.  The fused shell and liner are stronger and work together to absorb g-forces more efficiently. STRONGER WITH A PURPOSE.

 

 

 

CONES = CRUMPLE ZONES

By incorporating multi-density EPS foam with geometric cone shapes into the liner, we create crumple zones.

This multi-density construction allows us to fine tune the EPS foam, putting the harder foam on the outside (light grey cones) to quickly dissipate high-g force impacts, while putting softer foam (dark grey cones) next to your head to cushion any blow. 

In an impact, the cones compress redirecting the energy laterally away from your head, reducing the chance of injury.

Benefits:

  • Better impact energy management, less force transferred to the head. 
  • Smaller helmet shell thickness, lower mass, less torque on the neck.
  • 15-25% softer foam next to your head.

 

MEET THE [CONEHEAD] FAMILY

Introduced in 2011, Composite Fusion Plus was the first variation of Composite Fusion and uses cylindrical cone-shaped. Composite Fusion now consists of three unique variations that incorporate cone-shaped foam. Each shape was developed in an effort to create a better performing, better energy absorbing, helmet shell. 

 

 

Composite Fusion Plus incorporates layers of multi-density cone-shaped foam into the helmet liner. The addition of the cones reduces impact g-forces by as much as 25%.

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Composite Fusion 3 incorporates layers of multi-density, triangular shaped cones, further increasing impact management efficiency. Because of this, we can reduce the thickness of the helmet shell and liner, making the helmet smaller (lower volume).

 

 

Composite Fusion Squared combines multi-density foam and dual direction geometric cone shapes. These opposing cones address both the ground-to-helmet impact as well as the helmet-to-head impact. 

 

IMPACT TESTING

Traditional vs. Composite Fusion