Kali fortifies helmet’s inner shell – with inverted pyramids

Publish Date: 
Feb 16, 2013
By Mike Vaughan

DEALER EXPO, Indianapolis, Ind. – What happens when you mix an aero-space engineer with motorcycles? Kali Protectives.

Brad Waldron, president, owner and chief engineer made the switch from working on B2 bombers and F18s to develop a better helmet initially for motocross, and now street.

The Kali helmet, named derived from the Indian Goddess of chaos and destruction, has combined several technologies to develop a helmet that breaks new ground in the helmet industry.

Virtually all helmets consist of two main elements, a hard outer shell made of fiberglass, carbon fiber, or some other type of plastic, and an expanded poly styrene inner shell. It’s a design similar to a picnic cooler.

Kali helmet’s outer shell is carbon fiber, the inner shell, like others, is also composed of a poly styrene material, but with a difference. The poly styrene material is constructed with dozens of inverted pyramids, with a second layer of a different density poly styrene molded into it, with a smooth inner surface. This inner liner is then bonded chemically to the shell, eliminating the usual space created by traditional spot gluing or tape used in other helmets.

This construction allows a thinner, but equally strong outer shell to do its job of resisting penetration, impact and abrasion, while disallowing a secondary impact as the outer shell is driven into the inner liner after the initial impact with conventional construction. The pyramids also aid in the dispersion of the impact over a wider range of the poly styrene inner liner, thereby lessening the total impact to the skull, acting in a similar manner as the “crumple” section of a modern automobile.

The Kali helmets, shown at Booth 707, are not only stylish, but lighter and at least as strong as conventional helmets. In addition to full-face and motocross helmets. Kali also makes a “beanie” that uses the same technology, creating a smaller and lighter helmet that actually offers a significant degree of protection compared to the average “beanie.”