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KAV Helmets designs and manufactures 3D-printed cycling helmets at its production facility in Buffalo, New York. The company was founded by Whitman Kwok, who spent more than seven years developing a 3D-printing process for customized bicycle helmets before opening KAV’s first facility in Redwood City, California. In 2023, after winning $1 million in the 43North startup competition, Kwok relocated manufacturing to a roughly 7,000-square-foot facility in Buffalo’s Old First Ward, citing the city’s skilled labor pool and lower operating costs. KAV produces helmets through a made-to-order process using 3D printing, which the company says eliminates excess inventory and production waste compared to traditional helmet manufacturing. The Rhoan line is custom-built from individual head scans, while the Silvo line is a ready-to-wear helmet shaped using data from more than 5,000 rider head scans and offered in three sizes. Both helmet lines are designed, printed, and assembled at the Buffalo facility, and each custom Rhoan helmet is delivered four to six weeks after a customer’s fit is finalized.
