KAV Helmets made a name for itself with its unique-looking custom-fit 3D-printed helmets. Now, the brand is introducing the Silvo, a new, non-custom, ready-to-wear road cycling helmet shaped by thousands of custom-fit head scans. With its 3D-printed hexagonal structure and signature KAV styling, it bears a striking resemblance to the custom-fit Rhoan, but sells for 2/3 the price.
The Silvo helmet is still made in the U.S.A. and boasts an impressive 5-star rating from Virginia Tech, but with its off-the-shelf fit, it has no lead time, and it retails for $100 less than its custom counterpart.
KAV Silvo Details
The biggest story with the Silvo is that it is not custom-fit like the Rhoan. Instead, KAV has taken data from thousands of custom-fit head scans to create its shape. KAV says this data means that the Silvo is shaped for the head first, rather than needing to be adjusted to it. According to the brand, “each size reflects real human variation — not simply scaled shells.”
Additionally, the Silvo includes a wraparound retention system with a self-adjusting rear cradle that they say “settles naturally into place.” KAV states that the Silvo’s intelligent fit results in security that doesn’t require overtightening, providing rough-road stability, all-day comfort, and consistency. While it isn’t specified, it also appears the small ports on the front of the helmet are intended for sunglasses storage.
Safety First
Like the Rhoan, the Silvo is also designed and built around KAV’s “structural energy management” philosophy. This includes its signature 3D-printed hexagonal structure, which they claim is “engineered to deform differently depending on how and where impact occurs — helping distribute energy more intelligently across the helmet.”
Rather than relying on Mips or a similar system, the 3D-printed structure is designed to manage energy from direct and rotational impacts with internal reinforcements, crumple zones, and controlled shearing built in. This includes what the brand refers to as a “responsive exterior structure” with engineered structural slotting in the outer hex lattice that aims to “manage rotational forces before they travel deeper into the helmet.”
KAV has also added a “densified internal architecture” to add internal reinforcement and structure to handle a large range of impact forces. Combined with the responsive exterior structure mentioned above, they say this creates “a helmet that balances controlled exterior response with a stable, reinforced internal core.”
5-Stars
How well does KAV’s approach to helmet safety work? According to Virginia Tech’s independent test lab, it works quite well. The Silvo earned a coveted 5-Star rating and is currently ranked #23 out of all the bike helmets tested. With lower scores equating to better protection, the Silvo’s score of 8.96 ranks it as safer than the custom-fit KAV Rhoan at 9.26, although that helmet still gets a 5-Star rating at #32 on the list.
Ventilation
With large intake vents at the front, a massive exhaust vent at the rear, and the open hexagonal structure, the Silvo looks well-ventilated. KAV says the open internal structure, suspended fit system, and central airflow channel provide consistent, steady airflow over the head “without excessive bulk of insulation trapping heat.”
Warranty
The Silvo is made in the U.S.A., which KAV states gives them close control over materials and the manufacturing process. With quality materials, reinforced edges, and tight tolerances, KAV wants the Silvo to stand the test of time, and that’s reflected in the helmet’s impressive 5-year warranty. On top of that, they offer a 30-day perfect-size guarantee so you can ensure it’s the right fit before committing.
KAV Silvo: Sizes, Colors, Pricing, and Availability
The Silvo comes in three shell sizes, S (54-57cm), M (56-59cm), and L (58-62cm), and is offered in four colors: Polar White, Atomic Black, Midnight Navy, and Stone Grey. And unlike KAV’s custom-fit helmets, the Silvo is ready to ship with no lead time.
The new Silvo helmet retails for $200 and is available now. Head to the KAV website to learn more or pick one up for yourself.
