Send Nods Nightvision began in 2021 by focusing on night vision accessories and, over time, sought out new and innovative solutions. They progressed from developing a bridge system for PVS-14 night vision using 3D printing technology to creating padding systems for ballistic helmets that may revolutionize the defense industry.
The secret ingredient is elastomeric polyurethane.
They first learned about the lattice system after noticing it in Adidas shoes. Tim Pausch, the owner of the company, points to his sneakers as we sit for an interview. He notes that the soles in his shoes and the innovative AirPad systems for ballistic helmets are made of essentially the same material.
How is it possible? The machinery and processing are particularly innovative. Carbon employs a method known as Digital Light Synthesis (DLS), which involves printing liquid material using light to harden it directly on the building platform. Significant investments were made, resulting in the unique industrial 3D printing method. This process allows the production of over 600,000 pairs of shoes each year from Adidas and other manufacturers, featuring 3D-printed soles that cannot be replicated at home. Carbon reports the material can endure approximately 350,000 full compression cycles before it begins to weaken. Additionally, temperature variations are not a concern, as the material can function effectively between minus 20 and 60 to 70 degrees Celsius. After the printing process is complete, the material undergoes a baking process at elevated temperatures.
During the collaboration between Send Nods, RPM GmbH, and Carbon, they encountered the lattice structure, a self-supporting structure that sparked numerous ideas for its application. This led Send Nods to focus on ballistic helmets, addressing the significant issue of traumatic brain injuries in the field. Currently, at Send Nods, AirPads made of EPU43 (elastomeric polyurethane) have passed tests according to ballistic and industrial standards.
How does it work?
The air pad system includes nine individual pads: three large and six small, designed to fit in any helmet with a pad system.
“We figured out how to place them in the helmet. That’s our recommendation, but many of our customers place them as they prefer, because not every head shape is the same,” says Pausch, when asked about customization. He states it’s a one-size-fits-all product. “With the air pad, we have a two-centimeter-high pad featuring two zones. The first zone on the lower side, the impact zone, has a denser structure to absorb and dissipate impact energy. Then we have the comfort zone, which is open and larger to distribute the helmet’s weight evenly, without crushing into the impact zone or pressing onto the head. The pad also reacts with your body heat, softening after 15-20 minutes of wear so you barely feel the helmet.”
AirPads could be an excellent alternative to traditional solutions. The material is akin to memory foam, retaining its shape momentarily when compressed before rebounding. This, combined with the lattice structure, effectively dissipates energy. The design’s self-supporting struts absorb rather than transfer energy. Ballistic assessments using VPAM Soap Heads showed reduced back face deformation on both the head and helmet. Pausch notes that independent tests have shown that AirPads significantly reduce back face deformation, resulting in nearly zero trauma impact on the head. Previously, trauma levels ranged from 20 to 30 millimeters, but this innovation brought them down to negligible levels. In addition to technical benefits, the pads also enhance comfort:
“The whole structure allows air to flow around your head, so body heat can escape. After 20 to 30 minutes, you barely feel the helmet anymore. It sits like a cloud. That’s not just me saying it; our customers tell us this,” Pausch shares.
Will Send Nods Lattice become the new norm?
As Pausch notes, the new invention is already in use—not only by Adidas but also in American football:
“They 3D-scan professional players’ heads and print helmets that fit perfectly. So, the possibilities are wide,” says Pausch about the US manufacturer of football helmets.
Although high production costs currently limit this technology, the pads’ life-saving benefits make further development worthwhile. The AirPads system costs about 200 euros. The company, however, is actively working on improving and developing the system.
“The future will bring us more and more efficient products, offering greater security to soldiers, police, and anyone needing ballistic protection. We are working on new solutions, which will be available starting next year.”
While Send Nods Nightvision’s latest advancements remain guarded, BodyArmorNews.com is committed to staying updated about the developments in Send Nods’ lattice products.
