maxSHELL®: Robust. Lightweight. Structurally well thought-out.

maxSHELL®: Robust. Lightweight. Structurally well thought-out.

maxSHELL® is KED's own helmet construction for everyone looking for a robust, lightweight and durable shell solution. After the foaming process, the technology permanently bonds the EPS inner shell to the outer shell, the so-called microshell, using a special bonding process. The result is a sandwich composite with high elasticity and very good damping properties.

For KED, maxSHELL® is more than a technical detail. The construction stands for a clear development approach: protection, stability and everyday usability should not come together by chance, but be deliberately engineered.

What is maxSHELL®?

At KED, maxSHELL® refers to a proprietary shell construction for bike helmets. It centers on two components: the EPS inner shell as the shock-absorbing core and the microshell as the outer shell. After the foaming process, both are inseparably joined using a special bonding process.

maxSHELL® is not just a label, but a concrete engineering solution. With it, KED relies on a stable bond between the relevant helmet components instead of simply layering them next to each other.

    How maxSHELL® works technically

    • EPS inner shell as the functional core

      The EPS inner shell performs a central task in the helmet: it forms the basis for its damping properties. This is exactly where maxSHELL® comes in. After the foaming process, the EPS structure does not stand alone but is permanently bonded to the outer shell. The inner shell thus becomes more than an isolated protective layer: it is part of a coordinated construction. The result is a helmet structure designed for technical stability and controlled elasticity.

    • Microshell as the outer layer

      The upper shell, referred to in KED texts as the microshell, structurally complements the EPS inner shell. It handles the outer shaping and helps give the helmet its robust, closed look. The interplay is clearly defined: the inner shell absorbs, the microshell stabilizes.

    • The bonding process as the connecting element

      The decisive step in maxSHELL® is the bonding process. The EPS inner shell and microshell are inseparably joined. Through bonding, two components become one compact, resilient composite with a defined structure and clean force distribution.

    • The sandwich bond as a design principle

      maxSHELL® is described by KED as a sandwich construction: a damping inner shell, an outer shell and, between them, a permanently bonded unit. The advantage lies in the combination of elasticity, stability and material efficiency.
    Crom - white orange matt

    What advantages does maxSHELL® offer?

    Robust helmet construction

    KED explicitly describes maxSHELL® as robust. A robust shell helps the helmet keep its shape and character in daily use.

    Very good damping properties

    The EPS inner shell is the technical starting point; the bonding with the microshell creates the structural connection. This aligns the helmet structure towards balanced protective behavior.

    High elasticity in the bonded structure

    With maxSHELL®, KED highlights the higher elasticity of the sandwich composite. The construction is not just hard and compact; it is designed for balanced behavior under load.

    Durability in daily use

    If you ride often, you want a shell construction that does not lose its effectiveness or appearance after a short time. This is exactly where KED's commitment to durability comes in.

    Comfortable, lightweight feel

    KED describes maxSHELL® as a lightweight helmet construction. A helmet is only worn gladly when it feels as unobtrusive as possible on the head.

    Who is maxSHELL® especially relevant for?

    • For everyday cycling

      For everyday cycling

      maxSHELL® is especially interesting for riders looking for a helmet that simply works in everyday life. City traffic, short distances, daily rides and changing weather conditions place high demands on helmet architecture. A robust, lightweight shell construction is a real advantage here.

    • For families and child-focused use

      For families and child-focused use

      Especially with family and kids' helmets, a mix of stability, easy handling and a reliable material feel counts. maxSHELL® fits exactly into this environment.

    • Crom - grey lilac matt

      For everyone who values technical clarity

      The technology is easy to explain, technically comprehensible and clearly distinguishable from the rest of the range. That is exactly what strengthens trust in the brand.
    Innenansicht eines KED Helms mit Polsterung

    maxSHELL® compared to In-Mold

    Two different design approaches

    In-Mold describes a seamless, high-strength bond between the outer shell and the EPS inner shell that is created during the foaming process. The advantage lies above all in a seamless design with very low weight and a good safety reserve.

    maxSHELL® follows a different approach: the EPS inner shell and microshell are joined by bonding after the foaming process. The focus is on the elastic sandwich structure, which is designed to be robust and durable.

    When each technology makes sense

    In-Mold is particularly suitable when a seamless construction and a very light helmet are the priority. maxSHELL® is a particularly good fit when the construction is meant to be designed for robustness, durability, and a clear shell bond.

    Which KED helmets use maxSHELL®?

    maxSHELL® is used in the following KED helmets: Kailu, Kailu Swiftie, 5Forty, Street Jr. Pro, Meggy II K-Star, Meggy II Trend, Meggy II Trend Uni, Meggy II Originals, Rayzon, Citro, Citro Special Edition Fan Germany, Spiri II Trend, Crom and Crom Swiftie. Want to take a closer look at a KED helmet with maxSHELL®? Discover the matching models and compare the shell construction with In-Mold and other KED technologies.

    To the product overview
    • Kailu

      Kailu

      €59,95 EUR
      €59,95 EUR
    • KED 5forty BMX-/Dirt-Helm in Petrolblau, Seitenansicht
      Up to 25% discount

      5Forty

      €48,71 EUR
      €48,71 EUR €64,95 EUR
    • Street Jr. Pro - arcadia green orange matt
      bestseller

      Street Jr. Pro

      €64,95 EUR
      €64,95 EUR
    • Pferdefreunde - Meggy II Originals

      Pferdefreunde - Meggy II Originals

      €54,95 EUR
      €54,95 EUR
    • Rayzon

      Rayzon

      From €99,95 EUR
      From €99,95 EUR
    • Citro

      Citro

      From €89,95 EUR
      From €89,95 EUR
    • KED Spiri II Trend Helm in Weiß matt, Seitenansicht
      bestseller

      Spiri II Trend

      From €69,95 EUR
      From €69,95 EUR
    • KED Crom MTB-Helm in Rot-Schwarz glänzend, Schräg-/Seitenansicht
      New colors

      Crom

      From €89,95 EUR
      From €89,95 EUR
    • Crom Swiftie

      Crom Swiftie

      €89,95 EUR
      €89,95 EUR
    • Kailu Swiftie

      Kailu Swiftie

      €59,95 EUR
      €59,95 EUR
    • KED Meggy II Trend Kinderhelm mit Dino-Motiv, Seitenansicht
      bestseller

      Meggy II Trend

      €49,95 EUR
      €49,95 EUR
    • KED Meggy III Trend Kinderhelm in Flamingo-Rosa, Seitenansicht

      Meggy II Trend Uni

      €49,95 EUR
      €49,95 EUR
    • Meggy II K-Star

      Meggy II K-Star

      €69,95 EUR
      €69,95 EUR
    • Citro Fan Germany - Deutschland Matt

      Citro Special Edition Fan Germany

      €89,95 EUR
      €89,95 EUR

    What does maxSHELL® mean at KED?

    maxSHELL® is KED's own helmet construction, in which the EPS inner shell is permanently bonded to the microshell after the foaming process using a special bonding procedure.

    Is maxSHELL® the same as In-Mold?

    No. At KED, In-Mold describes a seamless, high-strength bond created during the foaming process. maxSHELL® relies on a sandwich construction in which the EPS inner shell and microshell are bonded after foaming.

    What are the advantages of maxSHELL®?

    For maxSHELL®, KED highlights above all a robust and lightweight helmet construction, very good damping properties, higher elasticity in the bonded structure and long durability.

    Why is the sandwich construction important in maxSHELL®?

    The sandwich construction joins a stable outer shell and a shock-absorbing inner shell into one functional unit. The result is a helmet structure that is technically clearly defined and stands up to everyday use.

    Is maxSHELL® KED's own development?

    Yes. maxSHELL® is anchored in the shop as KED's own technology and is listed there as a clearly named helmet construction.

    Which KED helmets are equipped with maxSHELL®?

    maxSHELL® is used in the following KED helmets: Kailu, Kailu Swiftie, 5Forty, Street Jr. Pro, Meggy II K-Star, Meggy II Trend, Meggy II Trend Uni, Meggy II Originals, Rayzon, Citro, Citro Special Edition Fan Germany, Spiri II Trend, Crom and Crom Swiftie.

    Other technologies in KED helmets