Yes, it's scalable, but that is still the most challenging part. Traditional foam materials are relatively inexpensive and die cutting sheet foam or molding foam is faster than 3D printing. 3D printing is more of a top price point technology right now and I wouldn't expect to see it in any lower price point / value products in the next few years
For protection, the best think I can think of VT ratings? I know it's not perfect and people could find flaws in it, but I don't see any equipment OEMs publicly presenting safety data. VT is the only neutral source I am aware of? I would expect this helmet to be rated there and I check for it personally, I want to see that we did a good job.
Yes, hockey helmets have the same concept. There are foams specifically designed for safety or absorption and others designed for comfort. That is why traditional helmets have multiple foams inside the liners. They are designed to balance weight, comfort, and safety. With 3D printing, you vary the diameter of the lattice strut, the shape of the cell, and/or the base feed stock material to reach the same goals. Our IP, which Bauer uses, is about the lattice shapes morphing into each other. That will most closely mimic the traditional concept of multi-density foams fused together.
Yes, the shell is the same as the Re-Akt 150. The software decides if you are a S, M, or L shell and then it wraps the lattice around your unique head shape, creates a build file, and then the parts are built.
The parts are printed contoured / round and uniquely to your head shape. The parts look like a piece of cantaloupe almost. Check out the images I posted above. Top right image is exactly what the printed part looks like. It's contoured.