Rhoan: CORE

$300
49reviews

What hits the wind first matters most.
Most helmets force a choice: speed or cooling. Rhoan is built different—3D printed to channel air, shed heat, and custom-built to your exact fit.
Benchmark aero. Airflow you can feel. Comfort all day.

Polar White / White
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Polar White / White
Polar White / White
Polar White / White

Rhoan: CORE

$300
49reviews
What hits the wind first matters most. Most helmets force a choice: speed or cooling. Rhoan is built different—3D printed to channel air, shed heat, and custom-built to your exact fit. Benchmark aero. Airflow you can feel. Comfort all day.

Custom-built. Delivered in 3–4 weeks after fit approval.

Shells:
Hex Structure:

Custom-built. Delivered in 3–4 weeks after fit approval.

Benchmark aero • Airflow you can feel • Virginia Tech 5-Star Safety Rating • BEST NEW BIKE GEAR: SEA OTTER 2025, GEAR JUNKIE

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30-Day: Full Refund Guarantee
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100% Crash Replacement Program
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5 year warranty
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Made in USA

1: Order & Scan

After your purchase you will receive an order confirmation email with a link to download our KAV Fit App.Using just one photo, our app captures every contour, every curve of your head, ensuring your helmet is crafted to match your unique shape.

2: Fit Confirmation

After receiving your scan, we 3D print a "Fit Cap" mirroring your future helmet's interior. This cap is sent to your doorstep, allowing you to experience the fit and comfort firsthand.Your Fit Cap, comes with a QR code that you scan providing options to approve the fit or request adjustments, ensuring your helmet will be perfect.

3: Craft & Delivery

Once you approve the fit cap, our experts start the meticulous process of crafting your helmet. We adjust every detail to match your unique head shape, ensuring optimal comfort and protection.

Learn More Here

Rhoan stands among the fastest helmets on the market, within 0.001 CDA, or ~1 watt at 40km/h—while delivering airflow, cooling, and comfort they can’t touch.

The Rhoan earned a 5-Star Virginia Tech Safety Rating through a ground-up reengineering of impact protection.

At its core is our Hex Honeycomb Structure 2™ — a dual-density, 3D-printed lattice with independent hexagonal cells that deform asymmetrically to manage both linear and rotational energy.

This architecture eliminates the need for traditional slip-plane systems by integrating rotational management directly into the structure, resulting in lower weight, improved ventilation, and uncompromised real-world performance.

A 1°C rise in core temperature can reduce performance by up to 1.5%.

The Rhoan is made from our proprietary PolyCarbon Composite™ that wicks heat 8x better and cools 2x faster than standard EPS foam—helping you delay thermal fade and hold watts longer.

The Air Fit Suspension and HexFlow™ Rear Exhaust work together to create full-helmet airflow. Heat is actively pulled away from your scalp—maintaining focus, control, and comfort, even on the hottest days.

Our next-gen Hex Honeycomb Structure 2™ acts as a thermal scaffold, channeling air through its open-cell design. It improves both impact absorption and heat dissipation without adding weight or bulk.

Designed and manufactured in the USA using a net zero production process—delivering innovation, sustainability, and performance without compromise.

What People Are Saying

Very light and comfortable. I like the style and it was a very easy process to get fitted for this unique helmet.

Richard. _ 12/30/25

As someone who was always on the smaller side of a medium, but too large for a small, I had to put up with helmets that looked oversized and needed to be ratcheted down to stay put. This one fits so well I don’t even need the ratchet.

Lane. _ 05/13/26

It feels great throughout long rides and I even forgot to take it off after a ride recently! Do yourself a favor and order the perfect helmet - for comfort, safety, design, weight, and ventilation!

Claudia G. _ 11/06/25

I always stick to the same couple of helmet brands because I know they fit. I’m hesitant to try something new if I can’t try it on but that wasn’t the case with KAV. The process was easy and the helmet fits perfectly!

Jake. _ 04/27/26

I finally have a helmet that doesn’t look ridiculous on my head.

Michael. _ 03/05/26

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Aerodynamics That Actively Cool

Engineered to harness the Venturi effect, the HexFlow™ Rear Exhaust accelerates air as it exits the helmet—pulling heat and moisture away from your head with every effort.

Working in tandem, the Air Fit Suspension System lifts the helmet off your scalp to create uninterrupted airflow throughout. The result: better cooling, reduced core temperature, and sustained power when it matters most.

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2x Larger Front Vents

Strategically placed lower on the brow to funnel cooling air directly to the forehead, where thermoregulation is most effective.

It’s not just about vent size—it's about vent placement that works with your physiology.

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A Fit That Breathes

Our Air Fit Suspension System™ suspends the helmet off the head, eliminating pressure points and maximizing ventilation.

This all-around airflow helps reduce hot spots and maintain a cooler, more stable core temperature throughout your ride.

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5-Star Virginia Tech Safety Rating

The Rhoan’s Hex Honeycomb Structure 2™ uses a dual-density, 3D-printed design that adapts independently on impact — absorbing energy from both direct hits and rotational forces.

This advanced structure eliminates the need for bulky add-ons, reducing weight while enhancing real-world safety and comfort.

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Lock In. Ride On.

Redesigned and 3D printed for real-world use, the new sunglass ports make it easy to stow your shades mid-ride—and keep them secure, even over rough terrain. No slipping. No rattling. Just smart, ride-ready utility.

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GET OUT THERE™

SPEED MATTERS EVERYWHERE

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HOW WE COMPARE

The future of personalized performance

108 Measurements, 1 Perfect Fit

Optimized for Rotational & Linear Forces

Virginia Tech 5 Star + 50% Above CPSC Safety Standards

Crash Replacement

Warranty

Proudly Crafted in the USA

KAV3D
PRINTED HELMETS

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100%

5 Years

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TRADITIONAL EPS
FOAM HELMETS

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35%

2 Years

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Frequently Asked Questions

After your purchase you will receive an order confirmation email with a link to download our KAV Fit App.

With a few simple taps, our KAV Fit App will capture your unique contours, for a helmet that’s made exclusively for you.

Our KAV Fit App uses a single photo to extract over 100 data points from 18 facial features — leveraging advanced image analysis to ensure a personalized, precision fit.

The whole process from order to delivery of your custom helmet takes as little as two weeks + shipping.

The Rhoan earned a 5-Star Virginia Tech Safety Rating through a ground-up reengineering of impact protection.

At its core is our Hex Honeycomb Structure 2™ — a dual-density, 3D-printed lattice with independent hexagonal cells that deform asymmetrically to manage both linear and rotational energy.

This architecture eliminates the need for traditional slip-plane systems like MIPS, by integrating rotational management directly into the structure, resulting in lower weight, improved ventilation, and uncompromised real-world performance.

Features unique to the new Rhoan Helmet:

•The Rhoan is 20% lighter than the Nova

• 6mm on average narrower than the Nova

• The interior has been redesigned with our all new internal Air Fit Suspension and HexFlow™ Rear Exhaust, which work together to create full-helmet airflow. Heat is actively pulled away from your scalp—maintaining focus, control, and comfort, even on the hottest days.

Every helmet is custom made so even for the same circumference, your head shape can change the size by +/- 20 grams. However someone who is in the middle of medium (~57.5 cm circumference) can expect their KAV Rhoan helmet to weigh 300grams.

Our helmets are engineered with our proprietary Hex Honeycomb Structure 2™ which has the most efficient energy absorption to weight ratio or crumple zone design to redistribute energy & force upon impact.

Yes, the Rhoan features a rear ratchet mechanism built into them that allows 8-10mm of travel ensuring both a snug fit as well as giving your custom helmet a bit of play to account for the winter season or a new haircut.

"This is the best helmet I’ve ever owned. Well worth the wait. Hardest part was adjusting the strap placement around my ears. Now all I have to do is put it on my head and clip the strap. No more adjusting the back closure and looking in the mirror to make sure it is not crooked on my head. Fits perfectly every time."

John M. ✅ Verified Reviewer

Overall rating: 4.8541665 / 5 from 48 reviews.

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Review highlights

Reviews

Great out of the box

"After a few hundred miles I can report that this is worth the money. Vents well, looks good and fits comfortably. There is a bit of a learning curve with sweat management, but as long as it isn't running into my eyes it's fine. The turn-around was under six weeks. As someone who was always on the smaller side of a medium, but too large for a small, I had to put up with helmets that looked oversized and needed to be ratcheted down to stay put. This one fits so well I don't even need the ratchet. Custom colors are a bonus. Overall no buyer remorse (and that is after trying on every helmet at Sea Otter this year)."

— happy r. (5/5)

Exceeded expectations and would buy it again

"I was in need of a new helmet as my Abus Gamechanger was aging out. I admit I was a bit skeptical of the 3D printed concept, but the custom sizing and crash ratings convinced me. Now that I have been riding with the helmet for a couple months now, I have to say I'm really happy with this helmet due to how it performs. The cooling vents are far superior to anything else I have ridden in the past. It's like having an A/C on your forehead in the summer. The fit is excellent and its well constructed. I like the all white colorway I was able to customize, and am pleased to not have to deal with foam pad cushions or inserts any longer. This helmet is the actual gamechanger."

— Daniel (5/5)

Hi-Vis Nova

"Love the Hi-Vis orange! Helps to safely stand out and be seen while in traffic. Distinctive design makes this helmet a cool stand out to all the other mass produced helmets. Lots of compliments. . . and "what brand is that helmet?"

— Christian M. (5/5)

Really nice. Heaps better than the Nova.

"It's really, really nice. I wish I could give it 4. 5 stars. If you had a Nova and didn't like it, give the Rhoan a shot. It's not that much lighter, but it FEELS way lighter. The dial fit is a total game changer. A nice bonus is the brow of the helmet sticks out enough that it's almost a mini visor."

— Littlewing (4/5)

Great Investment

"Helmet fitting process was very impressive and resulted in a snug by very comfortable fit. Love the color customization. Not the lightest helmet, but you can prefer the Rhoan is weight is a big concern. The main issue I encountered was a poor communication when my order was delayed due to operational shifts to the East Coast. The delivery times on the website now (8-10 weeks) are what I encountered but when I ordered my helmet it was a 4 week estimate. This was very frustrating when the helmet took exceptionally longer than promised with no explanation or customer service number to call."

— David W. (4/5)

SAVED MY LIFE? WHO KNOWS

"On July 22, 2025 I was involved in a serious automobile accident while riding my bike and wearing my KAV Rhoan helmet. I was struck by a vehicle traveling in excess of 60 miles an hour while I was riding about 20 mph. I’m a lucky guy as my recovery is basically waiting for bones to heal (fractured/de-gloved right hand, broken left ankle and fibula, a couple of broken ribs, spinous process C7, pubic ramus), dislocated right shoulder, and assorted road rash. No neurological injuries, no real cosmetic damage (I’m still just as ugly as ever, but no uglier - woot woot). Every medical professional that has seen my chart and heard my story cannot believe I’m not more neurologically injured. Thanks for producing such a great helmet. I’ll be thanking myself every day for buying one."

— James B. (5/5)

Crash Report-A+

"Been wearing my KAV Nova for less than a year but it is the only helmet I can get to fit properly on my very long, narrow head. Loved it for it's light weight, great air flow and comfort. Last month I had a crash while training. (Can't tell you why, as I have no memory of the crash. ) Hit the ground hard on my right at about 18mph, broke my hand and 2 fingers, my nose, sunglasses, bike, and helmet. CT scan was clear and had no obvious concussion symptoms (except for memory loss). Helmet shows signs of hard hit. Outer shell dented and small cracks. Inner shell is not visibly damaged. Most importantly, it stayed in place (good fit) and my head is intact. That crash would have been FAR worse without my KAV helmet. I am replacing it with another. They get my strongest recommendation."

— Kevin P. (5/5)

Best helmet I've ever had!

"20 rides in with my new helmet and love it! The fit is perfect, much better than all the "off the shelf" helmets I've had. Great airflow and sweat is channeled off to the sides of my face, not in my eyes. Awesome customer service, too. I don't often leave reviews but was compelled to leave one this time. Great job, KAV."

— Steve P. (5/5)

Hi-Vis Nova

"Love the translucent Hi-Vis orange! Lots of comments and compliments. When I stopped by KAV. Jordan and Mike were VERY helpful in fine tuning my helmet fit. Very professional, knowledgeable and friendly. I highly recommend KAV helmets for their quality, and customer service."

— Christian M. (5/5)

Nova Hi-Vis

"Love the bright Hi-Vis orange and unique design!"

— Christian M. (5/5)

Q&A