Scaling Custom Performance with CCM Hockey
CCM partnered with Toolkit3D to transform an elite custom helmet workflow into a scalable, scan-to-production system for 3D-printed lattice liners.
From Elite Customization to Global Scale
CCM Hockey set out to redefine helmet safety and performance with the Super Tacks X helmet liner, the world's first 3D-printed, lattice-based helmet insert.
The liner replaces traditional foam with a structure engineered for energy absorption, dissipation, airflow, breathability, and fit-specific deformation behavior. At first, that level of customization was only practical for elite NHL athletes using custom workflows driven by 3D head scans.
The Challenge: Custom Did Not Scale
The innovation was real and demand was massive, but the process required too much manual design effort to support mass adoption.
Manual lattice design and adjustment slowed each custom helmet.
Complex scan-to-fit workflows created high engineering overhead.
Computationally heavy design steps limited throughput.
Elite-only customization made mass adoption impossible.
Toolkit3D and Automated Scan-to-Production
Toolkit3D helped CCM industrialize customization by orchestrating scan capture, automated fit processing, Carbon Design Engine integration, design automation, and production-ready output.
Scan-to-Fit
Head scans are cleaned, normalized, and mapped to helmet zones so padding regions can be defined automatically.
Lattice Automation
Lattice density, strut thickness, and geometry are tuned algorithmically around impact, airflow, and comfort constraints.
Production Output
The workflow generates additive manufacturing files that integrate with CCM's existing production process.
Breakthrough: 8 Hours to 10 Minutes
Toolkit3D turned a manual, elite-only process into a fully automated workflow that could scale globally while keeping CCM's performance constraints embedded in the design process.
What This Unlocks for CCM
The partnership helps CCM bring elite-level fit to every player, expand beyond custom NHL workflows, reduce engineering overhead, and respond faster to demand spikes.
"We chose Toolkit3D to bring the custom-fit process used at the elite level to the masses, working toward an optimized, automated process to meet global demand."
"We allow CCM to customize at scale and low cost while respecting technologies already integrated."
Outcomes
Design time moved from roughly eight hours to about ten minutes per helmet.
CCM can bring elite-level fit beyond NHL athletes to a broader global player base.
Automated workflows reduce engineering overhead and lower per-unit production cost.
Algorithm-driven repeatability preserves performance standards across scaled production.
Ready to go from prototype to global production?
If your product depends on fit personalization, complex geometries, or manual workflows, Toolkit3D can help you scale.
Schedule a Demo