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Beyond Aero: How KAV is Reinventing the Bike Helmet from the Inside Out

The Gravel Ride. A cycling podcast

Release Date: 06/10/2025

Lost & Found: The Singular Cycles Story with Sam Alison show art Lost & Found: The Singular Cycles Story with Sam Alison

The Gravel Ride. A cycling podcast

In this special “lost episode,” I sit down with Sam Alison, the founder of Singular Cycles — a UK-based brand that’s been quietly ahead of the curve since 2006. Sam shares how his journey from Australian shop rat to UK-based frame designer was shaped by a lifelong love of bikes, and how his early experiments with 29ers and drop bars paved the way for what we now call gravel bikes. We talk about his iconic models like the Swift, Peregrine, and Griffin, the rebirth of Singular with titanium offerings, and his philosophy on timeless design, frame material, and rider-first geometry....

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Beyond Aero: How KAV is Reinventing the Bike Helmet from the Inside Out show art Beyond Aero: How KAV is Reinventing the Bike Helmet from the Inside Out

The Gravel Ride. A cycling podcast

Craig welcomes back Whitman Kwok, founder of KAV Helmets, to talk about the launch of their latest high-performance helmet, the Rhoan. They dive into the evolution of 3D-printed custom helmet technology, the bold move to open a new U.S.-based manufacturing facility in Buffalo, and how pro rider feedback helped shape the future of bike safety and performance. From tech talk to trail stories, this episode is a must-listen for gearheads and gravel cyclists alike. keywordsKAV Helmets, 3D printing, custom helmets, helmet technology, cycling safety, helmet design, manufacturing, aerodynamics,...

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Conquering the White Roads with Trek Travel: A Thrilling Gravel Experience at Strade Bianche Gran Fondo show art Conquering the White Roads with Trek Travel: A Thrilling Gravel Experience at Strade Bianche Gran Fondo

The Gravel Ride. A cycling podcast

Join host Craig Dalton and Trek Travel's Rich Snodsmith as they take you on an exhilarating journey through the heart of gravel cycling in Italy. In this episode of The Gravel Ride podcast, they share their recent experience at the Strade Bianche Gran Fondo trip organized by Trek Travel. With over three decades of friendship, these two avid cyclists reminisce about their chance meeting at the Lugano Cycling World Championships in 1996 and their shared passion for the sport. Throughout the episode, Rich and Craig discuss their incredible adventures, from vintage bikes at L'Eroica and witnessing...

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Tackling the 2024 UNBOUND 200 with Coach Justin Bowes show art Tackling the 2024 UNBOUND 200 with Coach Justin Bowes

The Gravel Ride. A cycling podcast

In this episode, Craig Dalton and Justin Bowes reflect on the lead-up to the Unbound Gravel 200 race, sharing insights into the unique training approach adopted to prepare for the challenging event. They discuss the strategic training block, the importance of quality over quantity, utilizing power meters for training effectiveness, and the significance of recovery in a compressed time frame. The conversation dives into the pivotal four-day mini camp, highlighting the benefits of stacking workload and the nuances of balancing intervals and endurance rides.  Join   Key themes include...

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Exploring the Gravel Roads of Colombia with Arriba Travel show art Exploring the Gravel Roads of Colombia with Arriba Travel

The Gravel Ride. A cycling podcast

This week we welcome Tomas Castrillon, the founder of Arriba Travel, to talk about the joys of gravel cycling in Colombia. We discuss the allure of traveling by bike, the unique cultural experiences that can be found off the beaten path, and the incredible diversity of Colombia's landscapes. Tomas shares his personal journey into the world of cycling and how it led him to create a bicycle travel company. He also provides insights into the specific route of Arriba Travel's Bogota to Medellin gravel trip, highlighting the challenging climbs, beautiful scenery, and rural communities that...

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I'm doing the UNBOUND 200 with FasCat Coach Justin Bowes show art I'm doing the UNBOUND 200 with FasCat Coach Justin Bowes

The Gravel Ride. A cycling podcast

This week on the podcast we welcome Justin Bowes, a coach at FasCat Coaching. We discuss the evolution of Fastcat Coaching and the development of their training app, Optimize. Craig shares he'll be lining up for the UNBOUND 200 in June and Justin has the tough job of getting him ready. Justin shares his background in racing and coaching and his love for gravel racing. They also dive into the specific challenges and strategies for training for the Unbound Gravel 200, including nutrition, hydration, and pacing. Justin provides valuable insights and tips for preparing for a long-distance gravel...

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Have a Good Ride Gravel: Building a Vibrant Community of Gravel Cyclists show art Have a Good Ride Gravel: Building a Vibrant Community of Gravel Cyclists

The Gravel Ride. A cycling podcast

In this episode, host Craig Dalton interviews Dean Dahl, the founder of Good Ride Gravel, about his journey into gravel cycling and the upcoming gravel event he is organizing in Chilliwack, British Columbia. Dean shares his background in skateboarding and mountain biking and how he found a similar sense of adventure and exploration in gravel cycling. He discusses the unique characteristics of the Chilliwack area, including its diverse terrain and the growing gravel cycling community. Dean also explains his vision for the Good Ride Gravel event, which focuses on creating a community-oriented...

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Andrew L'Esperance - professional gravel and MTB racer show art Andrew L'Esperance - professional gravel and MTB racer

The Gravel Ride. A cycling podcast

In this episode, Craig Dalton interviews Andrew L'Esperance, a professional cyclist from Canada. Andrew shares his journey in the world of cycling, starting from his early days racing with his brothers to becoming a professional athlete. He discusses the challenges and opportunities he has encountered along the way and how he has managed to make a career out of his passion for cycling. Andrew also talks about his transition to gravel racing and the different strategies and equipment choices involved in this discipline. He shares his experiences in races like Unbound and Sea Otter Classic and...

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Andy Lydic - the unofficial U23 Gravel World Chammpion show art Andy Lydic - the unofficial U23 Gravel World Chammpion

The Gravel Ride. A cycling podcast

In this episode, host Craig Dalton interviews professional cyclist Andy Lydic. They discuss Andy's journey in the world of cycling, from his early days in high school to his decision to pursue a career as a professional cyclist. Andy shares his experiences racing for amateur teams in Spain and his transition to gravel racing. He also talks about his participation in the UCI Gravel World Championships and his goals for the future. The conversation highlights the growing popularity of gravel racing and its potential as a pathway to professional cycling. Episode brought to you by . Join  ...

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Gravel Community Organizer, Andy Chasteen, Discusses the Rule of Three Event in Bentonville, AR. show art Gravel Community Organizer, Andy Chasteen, Discusses the Rule of Three Event in Bentonville, AR.

The Gravel Ride. A cycling podcast

Andy Chasteen, co-director of the Rule of Three gravel event in Bentonville, Arkansas, joins host Craig Dalton to discuss the vibrant gravel cycling community in Northwest Arkansas. They delve into the importance of connectivity and safe infrastructure for cyclists, the origins of the Rule of Three event, and the unique experience it offers with a combination of pavement, gravel, and singletrack. Andy also shares his perspective on event organization and the value of creating a memorable and enjoyable experience for participants. Don't miss this engaging conversation about the growth and...

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More Episodes

Craig welcomes back Whitman Kwok, founder of KAV Helmets, to talk about the launch of their latest high-performance helmet, the Rhoan. They dive into the evolution of 3D-printed custom helmet technology, the bold move to open a new U.S.-based manufacturing facility in Buffalo, and how pro rider feedback helped shape the future of bike safety and performance. From tech talk to trail stories, this episode is a must-listen for gearheads and gravel cyclists alike.

keywordsKAV Helmets, 3D printing, custom helmets, helmet technology, cycling safety, helmet design, manufacturing, aerodynamics, crash replacement, cycling gear
summaryIn this conversation, Craig Dalton speaks with Whitman Kwok, founder and CEO of KAV Helmets, about the evolution of the KAV brand, the innovative technology behind their custom 3D-printed helmets, and the recent launch of the Rhoan helmet. They discuss the challenges and successes of expanding manufacturing operations to Buffalo, the importance of aerodynamics and ventilation in helmet design, and the rigorous testing and safety standards that KAV Helmets adheres to. Whitman shares insights into the company's mission to provide confidence and safety for cyclists, as well as their unique crash replacement policy.
takeaways
  • KAV Helmets custom makes helmets using 3D printing technology.
  • The process involves taking a single photo to create a custom fit.
  • 3D printing allows for innovative designs not possible with traditional methods.
  • KAV expanded its manufacturing to Buffalo for better efficiency.
  • The Rhoan helmet was designed for both aerodynamics and ventilation.
  • Testing involved extensive wind tunnel analysis for validation.
  • KAV Helmets has a one-time crash replacement policy for safety.
  • The company adheres to high safety standards beyond regulatory requirements.
  • KAV Helmets aims to provide confidence in cycling activities.
  • The customization options allow users to express their creativity.
titles
  • Revolutionizing Cycling Safety with KAV Helmets
  • The Future of Custom Helmets: KAV's Journey
 
Chapters
00:00Introduction and Background of Kav Helmets
02:00Custom 3D Printing Technology
04:19Advantages of 3D Printing in Helmet Design
08:17Expansion and Manufacturing Journey
13:22New Manufacturing Facility in Buffalo
16:40Launch of the New Rhoan Helmet
18:22Innovative Design Features of the Rhone Helmet
22:32Innovative Helmet Design and Air Fit Suspension
24:58Aerodynamics and Wind Tunnel Testing
26:59Balancing Aesthetics and Performance
30:45Customization and User Experience
33:00Collaboration with Professional Athletes
34:38Crash Replacement Policy and Safety Standards
36:05Testing Standards and Internal Validation
40:10In-House Testing and Product Development
42:18The Evolution of Helmet Design and Safety Features
42:38New Chapter