FAQs

ABOUT KALI

• When Kali Protectives begin?

  1. 2008
• What makes Brad Waldron a helmet and safety expert?

Brad Waldron’s journey into the world of bicycle helmets began in 1997, when he joined Specialized Bicycle Components (SBC) as a helmet test engineer. This role followed his start as an R&D material process engineer at Northrop Grumman, where he specialized in carbon fiber parts for the B-2 and F-18E/F aircraft. At SBC, Brad spent countless hours in the test lab, impacting thousands of helmets to better understand the dynamics of an impact. His work in these early days highlighted the critical role EPS foam density plays in protecting the brain during crashes.

In 2005, Brad was approached by a helmet factory to improve its carbon fiber processes. Around that time, “in-molding” — the process of injecting protective foam directly into the helmet shell — was gaining traction within the industry. Bell Helmets had pioneered in-molding for thin-shelled bicycle helmets, which dramatically improved safety and ventilation compared to previous methods. However, due to technical limitations, in-molding had not yet been applied to full-shell motorcycle or downhill MTB helmets. While many believed this process was impossible for full shells, Brad, driven by his R&D background, saw potential. Once the in-molding process was under control, testing showed not only that the shell and foam could work in harmony, but also that this integration allowed for thinner shells and softer foam, significantly enhancing energy dissipation.

One advantage of working directly with factories was proximity to the production process itself — an approach few brands still follow, largely due to economic reasons. During Brad’s time in these factories, he noticed that many helmet designers only visited a few times a year, often leaving much of the engineering and safety testing to the factory. This experience taught him the value of collaboration, and he developed strong professional respect for the factory engineers, frequently seeking their insights.

As a large helmet factory, the facility attracted inventors and material experts eager to pitch their innovations. One of these pioneers was Don Morgan, an Australian physicist and cyclist who developed a concept called “Conehead.” Inspired by studies of bicycle accidents involving children, Don designed geometric shapes in the EPS foam to act like a car’s crumple zone, dispersing impact energy away from the brain. This structure enabled the use of multi-density foam in a highly effective way. By adopting this technology, Kali became the first to use Don’s Conehead concept in a helmet, a choice that reduced g-forces by up to 20% in lab tests. Many brands, such as Leatt and Fly Racing, soon adopted the technology as well.

Another notable collaborator was Dr. Dan Plant, a professor from the UK, who developed Armour Gel (now known as Rheon), a layer that absorbs energy more efficiently than traditional memory foam. Dr. Plant’s work provided Brad with insights into both linear and rotational energy dissipation, a crucial component of head protection.

Throughout his career, Brad has seen various materials and concepts, such as EPP, Koroyd, MIPS, and WaveCel, pass through these factories. Each brings unique advantages, though often with trade-offs. Witnessing firsthand the development and testing of these materials, Brad has gained a perspective that goes beyond the marketing narratives and focuses on tangible results in helmet safety.

Despite the high cost, Brad saw the safety benefits as undeniable, even if no established brand was willing to try such an “unproven” process. “If no one else will try it, we’ll have to do it ourselves,” he decided. In 2008, Kali was born, committed to pushing the boundaries of helmet safety.

TECHNOLOGY

• What is in-molding?
  1. The two main energy dissipation parts of the helmet are the shell and EPS foam liner. It is simply the process of injecting the energy dissipating part of the helmet (in most cases EPS) directly into the outer shell which creates a fusion between the two materials, eliminating any gaps, glues and tape which lessens energy spikes in the event of a crash, spreading the energy across the shell and EPS instead of it being sent directly to your head.
• What exactly is a Low Density Layer (LDL)?
  1. Low Density Layers (LDL) consists of specially designed padding that is placed throughout the interior of the helmet. It reduces rotational impact forces up to 25%, and reduces low-g linear forces up to 30%.
     
     You can learn even more about LDL here.
• Why does Kali Protectives have multiple versions of LDL and what are they?
  1. Kali is constantly looking for a better "mousetrap" for linear and rotational impacts. If there is a new material and it works, we will incorporate it into our line up.
     
     We have had a variety of iterations of LDL over the years. The first being BumperFit which was a simple, memory foam material that offered protection against lower-G hits. Since then, we’ve introduced RHEON, QuadCore and ERT.

SPONSORSHIPS + EVENTS

• Who do I contact about sponsorship?
  1. Please reach out to marketing@kaliprotectives.com and introduce yourself!
     
     
• I am throwing an event that I would like Kali Protectives to attend. How do I get that rolling?
  1. Please reach out to marketing@kaliprotectives.com with all of your event details and someone from our Marketing team will get back to you.

MILITARY/LAW ENFORCEMENT/FIRST RESPONDERS

• Do you offer a discount for Military/Law Enforcement/First Responders?
  
  
  1. Yes! Please reach out to contact@kaliprotectives.com, we kindly ask you to provide us with proof (ID, badge, certificate, etc.) that you do work in the above mentioned fields.

PRODUCT

• Where can I find a copy of the Bike Owner's Manual?

1. Bike Owner's Manual

• How do I remove the taillight on the commuter helmet?
  1. KALight Removal and Charging Video
     
     
• How do I swap out my street helmet face shield?
  1. Face Shield Removal & Installation Video
     
     
• Kali Protectives has many different full face helmets, how do I know which one to purchase for my type of riding?
  1. Kali Protectives offers a range of unique full-face helmets designed for different purposes. Let’s break them down so you can choose the best protective gear for you and your family.
     
     MAYA FULL FACE CHILD
     Perfect for young riders aged 3 to 6, the Maya Full Face Child helmet features a removable chin bar and an ERT Low Density Layer, providing essential protection as they learn to ride. It’s ideal for at-home practice with Mom and Dad, but it's not designed for BMX tracks or racing. This helmet is not recommended for smaller adults or teenagers.
     
     ZOKA
     The Zoka is an excellent entry-level full-face helmet, equipped with a sturdy ABS shell and an ERT Low Density Layer. Popular among rental companies, it’s a durable and cost-effective option that can withstand the demands of repeated use. The Zoka is strong enough for downhill racing and is a great choice for BMX tracks.
     
     INVADER 2.0
     The Invader 2.0 is a full-face trail helmet, engineered to keep up with the increasing capabilities of modern bikes. It’s designed for Enduro riders who push the limits on challenging trails. While it’s not intended for downhill racing, the Invader 2.0 features a 360° monocoque chin bar for added strength, along with ample ventilation to keep you cool and comfortable on the trail.
     
     DH INVADER
     For those looking to push the boundaries of what the Invader 2.0 offers, the DH Invader is the next step. Built to meet the stringent standards of downhill racing, this helmet features a less ventilated design to ensure maximum protection. The 360° monocoque chin bar provides the necessary strength, making it ideal for BMX tracks and downhill racing.
     
     OF INVADER
     The OF Invader follows the same design philosophy as the Invader 2.0, offering enhanced coverage without a chin bar. It provides deeper head protection than a typical half-shell, making it perfect for riders who demand more from their gear. However, this helmet is not DH rated.
     
     TRINITY/TRINITY CARBON
     The Trinity is designed for serious DH racing. You’ll see it in action at top events like Mammoth, Crankworx, and Whistler. This full-coverage helmet is available in both standard and full carbon versions, featuring an extremely strong chin bar with an ERT Low Density Layer.
     
     SHIVA 3.0
     The Shiva 3.0 is DOT rated, meaning it’s versatile enough to be worn on a motorcycle, side-by-side, or bicycle. This helmet is built for the most adventurous riders, offering multipurpose protection for whatever your ride brings.

GENERAL

• I saw that you just had a sale and I missed it, what can be done?
  1. The best way not to miss out is by signing up for our mailing list and following us on social media. This way you will know when our sales, Color Drops, events and promotions are.
• Do you have stickers?
  1. We do! Send us a postmarked envelope and we will send you back some stickers!

HELMET + PROTECTIVES CARE

• What is the recommended lifespan of a helmet?
  1. There isn't a cut and dry answer as there are multiple variables that can affect the lifespan of your helmet: how it was stored, heat, prolonged time in the sun or vehicle.
     
     Kali's rule of thumb is if you've crashed it, replace it. After 5 years of use, it's time to start thinking about your next lid.
• What is the recommended lifespan of your body armor?
  1. Body armor is a little different than helmets so the best thing to do is assess your gear: is it free from cracks, rips, tears, splits? It's probably fine but if you are having issues with fit after time or it's simply not functioning as it should, it's time to replace.
• How do I wash my helmet?
  1. For helmet care, mud and crud should be hosed off (do not use a pressure washer!). Wipe down gently with a wet rag to remove any surface dirt and avoid scratching the helmet. Allow time to air dry. Padding and liners should be hand washed.
     
     DO NOT use any harsh chemicals, contact cleaner or acidic chemicals to clean your helmet.
• Can I wash my protective gear?
  1. Most Kali Protectives protective gear can be machine washed in cold or warm water with a mild detergent and drip-dried. If you are unsure, simply hand wash.
     
     Knee and elbow guards with Velcro straps should be washed in a mesh laundry bag to prevent the straps from entangling or attaching to other items in the wash.
• How often should I replace my helmet if I have not had any crashes?
  1. There is no exact timeline for helmet replacements as the use life of a helmet will vary from user to user. The basic rule of thumb, regardless of use, is that you should replace most helmets after 3-5 years.
     
     If you ride 8-10 hours a week and wash your helmet and liners regularaly, you may be able to get 2 years out of a helmet before wear and tear. Remember: UV damage and the natural aging process of the materials also start to degrade the helmet's ability to protect you. The life of your helmet is decreased if you do not keep your helmet clean.
     
     If the helmet hits the ground in a crash, it should always be inspected before using it again. In a crash, the helmet can suffer damage that is not obvious to the untrained eye. This damage can inhibit the helmet's ability to absorb impacts and protect the user in a crash.

ACCOUNTING/PAYMENTS

• I am an Authorized Kali Dealer that needs to make a payment or change to my account, who can I talk to?
  1. Please reach out to your Inside Sales Account Manager with your questions and they will coordinated with Accounting.