KAV’s New Silvo is a More Affordable 3D-Printed Helmet That’s Ready-to-Wear 

KAV Helmets has launched the Silvo, a new ready-to-wear road cycling helmet that brings the brand’s advanced 3D-printed safety technology to a more affordable, off-the-shelf model. Unlike KAV’s previous custom-fit helmets, the Silvo is shaped using data from thousands of head scans to reflect real human variation, offering a fit designed to settle naturally without the need for adjustment. Priced at $200, it undercuts the custom Rhoan helmet by around a third, while maintaining the distinctive hexagonal structure and aesthetic that KAV is known for. The Silvo’s design centres on KAV’s “structural energy management” system, which employs a 3D-printed hexagonal lattice engineered to absorb and distribute impact forces intelligently. Instead of using traditional rotational impact systems like Mips, the helmet integrates internal reinforcements, crumple zones, and structural slotting to manage both direct and rotational impacts. This approach has earned the Silvo a 5-star safety rating from Virginia Tech’s independent testing lab, ranking it 23rd overall and slightly outperforming the custom Rhoan helmet in terms of protection. In addition to safety, the Silvo emphasises comfort and ventilation, featuring large intake and exhaust vents alongside an open internal structure that promotes airflow without trapping heat. The helmet’s wraparound retention system includes a self-adjusting rear cradle designed to provide secure, stable fit without overtightening, making it suitable for rough-road conditions and extended wear. KAV also appears to have incorporated small front ports that may serve as convenient storage for sunglasses. Manufactured in the United States, the Silvo benefits from close quality control and durable construction, supported by a five-year warranty and a 30-day perfect-size guarantee. It is available in three shell sizes and four colour options, with immediate availability and no lead time, marking a significant step in making high-tech 3D-printed helmet safety more accessible to a wider audience. The launch of the Silvo suggests KAV’s intent to expand beyond custom helmets while maintaining its reputation for innovation and protection.