In-molding technology merging the shell and foam liner. Better impact energy management, increased dynamic range - smaller, lighter and stronger.

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Kali Protectives came from a breakthrough in safety technology - COMPOSITE FUSION, a process that bonds the helmet shell and foam enabling us to use a thinner shell, creating a lighter stronger helmet. 

Lighter and stronger means a safe helmet with less mass attached to your head. In a crash, less mass attached to your head reduces impact g-forces acting on your brain.

No safety technology exists that can completely prevent injury, but we can significantly reduce the chance of trauma. Are we as helmet manufacturers doing enough? The more we learn and the more we understand, the better protective gear we can produce.

That is our goal at Kali - to deliver the best protection available to riders.










While dozens of manufacturers in the powersport world utilize dual density foams, they are generally assembled like the layers of a cake. Our COMPOSITE FUSION™ Plus Technology uses a layer of multi density cone shaped foam that intersect with a layer of softer foam that surrounds the head. In an impact, these cones act as a progressive damper to absorb different levels of impact. As they collapse, these cones also direct energy sideways and away from the brain.

View all Composite Fusion Plus Helmets >>


Mind the Gap
Note the gap between the shell and the inner foam in a traditional helmet - that’s what creates the double impact curve seen on the graph. That gap can add to head trauma in a crash. Current helmet safety standards are based on experiments conducted over 50 years ago, well before our current knowledge of concussive and sub-concussive impacts, as well as rotational injuries. To pass these standards, helmets constructed using traditional methods utilized hard shells and very stiff foam, compromising their ability to perform at low to medium speed impacts.




When we first began experimenting with materials to help reduce low-g or subconcussive impacts that are below the threshold of our current foam liners, we tested a number of materials until we found a type of vinyl nitrile we call Bumper Fit. This substance is similar to Poron or D30 and hardens on impact to help provide some low-G protection. The material also acts as a memory foam, which helps to reduce hot spots and increase comfort.

We call the latest iteration of this technology LDL, or Low Density Layer. It consists of specially designed viscoelastic padding that is placed throughout the interior of the helmet. It reduces rotational impact forces up to 25%, and reduced low-g linear forces up to 30%.

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We're constantly testing new technology and after experimenting with dozens of different geometric shapes, we found a pyramid shaped that was better at dissipating forces than the our existing conehead technology in certain applications. Like Composite Fusion™ Plus, this tetrahedral layer of multi density EPS foam is able to act as a progressive damper to absorb different levels of impacts, as well as help distribute energy laterally, but it also allows us to create a smaller and lighter helmet.

View all Composite Fusion Three Helmets >>


Combines multi-density foam and dual direction geometric cone shapes. Interior and exterior impact energy management.

View all Composite Fusion Squared Helmets >>



Acrylic self-healing foam infused with carbon nanotubes. Dissipates impact energy more efficiently than traditional EPS in a smaller volume.

View all Nano Core Helmets >>



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This is the promise we make to ourself.

To Engineer, design and produce the safest and most sought after helmets and protective gear in the world.


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