Case Study: Send-Nods Improves Tactical Helmet Comfort and Protection with Carbon DLS and rpm

Send-Nods and rpm Seek to Improve Comfort and Protection for Tactical Helmets

Send-Nods, a military gear company, wanted to improve comfort and protection in tactical helmets for European users by replacing traditional foam padding with a more breathable, load-responsive solution. To do this, Send-Nods worked with Carbon and its Digital Light Synthesis™ (Carbon DLS™) 3D printing process, using Carbon’s platform to develop the AirPad System for EU helmet sizes and regulations.

Carbon, working with production partner rpm, helped design and produce the AirPad System using Carbon’s Design Engine Pro™ software and EPU 43 material. The team created a tunable lattice padding system that improves airflow, comfort, and damping under heavy loads, and they moved through five design iterations in two months, including soldier field testing. The result was a first-to-market lattice helmet padding product for Europe that was ready for serial production within a few months.

Send-Nods

Tim Pausch

Owner