BASF Forward AM and Toolkit3D Make Mass Personalization Possible
Forward AM and Toolkit3D created an end-to-end solution for bespoke bicycle helmets, combining scan-to-fit automation with high-performance 3D printing materials.
Custom Helmets at Production Scale
Forward AM's Ultrasint TPU01 material produces strong, flexible, and lightweight lattices for custom helmets. Beyond material supply, Forward AM helped optimize the lattice and bring the ordering workflow together.
Toolkit3D's platform integrated laser scanning, product design, order management, and manufacturing so personalized helmets could move through a configurable workflow at mass-production speeds.
The Challenge
To prove mass personalization for bicycle helmets, Toolkit3D needed partners that could support both software-driven customization and the material requirements of a protective sports product.
Consumers needed a simple way to scan their heads, choose colors and textures, and order made-to-fit helmets.
Manufacturers needed scan data that could generate custom lattices for standard-sized bicycle helmet shells.
The lattice had to be strong, flexible, lightweight, impact-resistant, comfortable, and breathable.
The assembly needed modular, swappable parts that could connect without glue.
The Solution
Forward AM used Toolkit3D's Scan-to-Fit Design Engine to produce a helmet built from precise head measurements. Its lattice expertise helped improve comfort, reduce weight, and tune cushioning, rebound, and aeration around Ultrasint TPU01.
Precise Scanning
Head scans provided the measurements needed to generate custom lattices that fit inside standard helmet shells.
Optimized Lattices
Forward AM optimized repeating 3D shapes for shock absorption, comfort, breathability, and HP MJF production.
Manufacturable Assemblies
The team designed 3D-printed components to work with molded shells, clips, straps, and modular assembly requirements.
A Repeatable Path to Made-to-Fit Products
The collaboration showed how any product that can be scanned and customized can move through an end-to-end personalization workflow. Toolkit3D handled the ordering system and design automation, while Forward AM contributed material, lattice, prototyping, finishing, and testing expertise.
The Result
Together, Forward AM and Toolkit3D created an end-to-end solution that makes mass personalization possible for products built from scan data, configurable design, and additive manufacturing.
Read the original Forward AM articleOutcomes
Forward AM optimized the lattice structure around Ultrasint TPU01 for sports protection applications.
Toolkit3D connected scanning, product design, ordering, and manufacturing into one workflow.
The solution showed how custom products can be configured and produced at mass-personalization speed.
The helmet assembly supported 3D-printed components alongside molded production-quality shells.
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