nFrontier Builds Smart Bike Helmet “PYLO” with MakerVerse

nFrontier envisioned one of the safest, smartest bicycle helmets. 

An airbag around the face activates in the case of an accident. LED lights on the back of the helmet help cyclists safely signal. A LIDAR (light detection and ranging) safety system warns cyclists of potential dangers in blind spots.  
To turn that vision into a reality, nFrontier partnered with MakerVerse to 3D print a prototype of the PYLO helmet.


Innovation Studio


Berlin, Germany

Company size

20+ employees

Use case


Technology used

Stereolithography (SLA) 3D printing

Material used

PA 12 with priming and paint

Parts produced

An innovative helmet prototype


Expert guidance from MakerVerse helped find the best-fitting material, resulting in an impressive multi-part prototype

The outher shell of the helmet was primed and painted. 

The inner frame was also made using SLS 3D printing technology. 

Working with MakerVerse and leveraging their extensive eco-system to support on demand parts requirements has allowed us to be more responsive and agile. They have successfully delivered on what we have asked of them to date, and this allows us to focus our expertise on where it is most needed.

Stephan Beyer

Co-founder and CFO of nFrontier

The Challenges image The Challenges: Prototyping Perfectly

nFrontier felt the urgent need to enhance safety for cyclists, whether recreational riders or athletes. The team rigorously designed the helmet, which brought together technologies from the automotive, electronic, and computer industries.  
For nFrontier, a high-quality prototype was critically important. The prototype would be brought to trade shows, shown to media outlets, and used to attract future investment.

Therefore, the prototype must be expertly manufactured, visually striking, and lightweight.

The 3D-printed inner shell is lightweight. 

The Solutions iconThe Solutions: Shifting into High Gear

To achieve a prototype highlighting everything the PYLO helmet offers, nFrontier put their trust in MakerVerse. 
Before production began, nFrontier worked with MakerVerse’s expert engineering team to determine the best way to produce the parts.

Based on the project needs, MakerVerse recommended using Selective Laser Sintering, an additive manufacturing technology capable of complex, highly accurate polymer parts. The material used was PA 12, a polyamide with high strength and long-term stability.

Thanks to MakerVerse’s fully-vetted supply chain, the perfect manufacturer produced the parts, including the outer shell and intricate inner lining.

The Result iconThe Result: Pylo Pedals into the Spotlight

With the 3D-printed parts provided by MakerVerse, nFrontier was ready to show off the PYLO prototype to the world. 
nFrontier unveiled the helmet at the IAA Mobility 2023 motor show in Germany, generating a strong positive reaction from attendees 
and the media. Attendees especially noted the unique technologies and impressive design of the helmet. 
With the prototype completed, nFrontier looks forward to bringing the product to market to make cycling safer.

“MakerVerse helped make the prototyping process easy for us,” said Stephan Beyer, co-founder of nFrontier. “The team did a great job, from the initial planning to the quality control.”

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