Kali Naza Carbon - Amazingly Light and Protective Piece of Helmet Technology

The world of motorcycle gear often progresses at an oddly stilted pace, with many manufacturers simply going with the old adage of ‟if it ain't broke, don't fix it”. That's why I'm always excited to see new innovations and technology make their way to every day riders.

Kali Protectives is a five-year old helmet manufacturer you've probably never heard of. The company is based in Morgan Hill, California in the southernmost part of Silicon Valley, the global high- tech capital.

Bryan Mason of Kali Protectives explained how the company's innovative helmet manufacturing process increases head safety by 25%. ‟When you take an impact, it's a two-step hit. First to the fiber-glass outer shell and then a secondary impact or spike transfers to the foam which transfers to the head and brain. The shell spreads the load and the foam absorb the impact before it reaches the brain. So two impacts are dissipated by the helmet.”

The brain is suspended in fluid so even a micro second between both impacts means the brain gets hit twice and leads to increase in concussion and results in brain bounce. ‟We figured out how to make the shell and foam one piece by bonding the shell and the foam using Compost Fusion. This eliminates the secondary gap and the secondary impact to the brain."

Light weight, safer, carbon fiber helmets under $400 USD? Impressive. Kali Protectives sent over the Naza Carbon Lightness helmet so I could test and review it for myself. I'll share how the helmet handled later in my review, but first I want to explain the construction of the helmet, as it presents an interesting new take on the protective technologies Kali brings to their helmet construction process.

The Old Way - A Tale of Two Shells

Traditionally, motorcycle helmets have both a hard outer-shell designed to dissipate crash forces as well as protect the internal materials from sharp objects and abrasion during the impact. The inner-shell consists of an energy absorbing foam that is designed to reduce the damaging forces on your head.

In standard construction of a helmet, the outer-shell is crafted from materials like fiber and resin composites or polycarbonate plastics. This outer shell is constructed separately from the inner shell, made up of Expanded Polystyrene (EPS). The inner-shell is created by filling a mold of roughly the same shape and size with beads of EPS foam. The beads expand and form themselves roughly in the shape of that mold. Once the EPS foam has dried, it's pulled from the mold and either glued or taped into the outer- shell.

This process means that there isn't a perfect match between the inner surface of the outer-shell and the outer surface of the EPS form. That leaves a very thin layer of potential dead space between the two surfaces.

During a crash, as the impact energy is moving through the helmet, there is a very tiny, yet measurable, microsecond of time where the energy isn't dissipated, only transferred. When it comes to a crash, every moment of time, no matter how small, is important in mitigating damage.

The Kali team sought to improve on protective technology. In their research, measurements of energy dissipation during the initial impact actually showed a very brief moment where the g-forces were not being efficiently absorbed in the energy transition between the outer shell and the foam.

Improving the Process - Two into One

Kali has removed that inefficiency, and made a lighter helmet, by developing a new design for constructing their helmets. Instead of molding their internal shell separately, they spray the EPS foam directly into the inside of the shell, allowing it to form against the individual shell's shape and bond to the surface.This gets rid of the dead spots that reduce impact absorption. The process makes the internal shell less likely to come loose over time and move slightly within the helmet, as it could if simply taped or glued in traditional construction. Kali calls this their Composite Fusion construction.

According to the Kali team, the process removes the secondary spike in transferred forces, reducing impact effect by up to 25%!That process also makes use of dual-layer density foams, which help better handle those crash forces, but also make the shell lighter and thinner.

Kali has continued their research on the construction of the internal shell's foam makeup with a new way to design how those densities are layered. Calling this new design Composite Fusion Plus (CFP), the EPS shell has interlocking densities of foam that look like pyramids or spikes.

The pyramid shape helps redirect those forces sideways, away from your head. This allows Kali to shrink both the weight and thickness of their helmet further, while still complying with both DOT and ECE 22-05 protective standards.

Test Riding with the Kali Naza

The Naza Carbon helmet I tested features a carbon tri-weave shell that helps to make the outer protection stronger and lighter. Internally, it makes use of the added protection of the Composite Fusion Plus

I am generally a fan of pure white helmets for safety reasons, but the Naza carbon light weight design quickly won me over. There's plenty of shiny white areas along the helmet, with some black highlights and a patch of the carbon weave exposed under the resin on the top sides. The finish of the paint helps create a spectacular design when seen from all angles.

The plastic spoiler on the top back of the helmet could use some work, as there is just enough room between the plastic and the shell for scratches and debris to work their way onto the white plastic. It's not enough to ruin the looks of the helmet, but is noticeable when closely inspected.

Fortunately, Kali helps protect your helmet by providing a helmet bag in the box. This isn't just a cheap, thin bag, either, it's a full helmet carrier bag with straps, padding and good looking design. It was a great surprise to get an accessory you'd expect to pay extra for separately as included with the purchase.

When the helmet is picked up, it's a bit deceiving. It does feel light, but simply having in your hands really doesn't strike one the same way it does once the helmet is on your head. It's when you're strapped in that the weight savings of Kali's construction jumps out at you.

While out riding, I very quickly noticed just the mass difference any time I moved my head. The Naza makes it easy to keep your head on a swivel while checking for traffic around you. There's less lag in tilting or rotating your head due to the weight reduction. The thinner helmet and aerodynamic design also meant little in the way of buffeting even at highway speeds. I also noticed much less fatigue due to the weight savings, and could have stayed out riding much longer if it wasn't for the winter cold getting to me.

One area that I had a concern with due to the new construction was ventilation. Many helmet makers actually rely on the air gap between the inner and outer shells to help move air along the top. While I didn't have a hot summer day to test against, the air vents did seem to provide adequate amounts of air during the ride. I suspect the thinner shell will help mitigate at least some of my concerns once the warm weather returns.

Some areas that Kali could improve on the helmet are more along the lines of fit and finish to the internals. The inner fabric is comfortable, but could be a bit better constructed. The nose and breath defector was a bit deformed, but not enough to bother me once on the road. Having gotten used to ratchet-style chin straps, the D-ring strap could stand to have a bit less material hanging in the wind.

Kali also sent me two additional face shields to test with the helmet. The shield options for the Naza are limited to a dark smoke and a light smoke with silver finish. Both really looked great on the helmet. The silver visor really brought out the silver highlights of the helmet's paint scheme. I would like to see Kali improve the shied locking mechanism, as changing shields took some practice. As a rider that rides in both high and low temperatures, I'd also like to see a pinlock option available to help reduce internal fogging of the shield.

Considering the price, those are not big concerns. The standard Kali Naza helmet is currently available for around $150 online, whereas similar priced helmets from competitors are heavier and more prone to finish issues.

The Naza Carbon is more expensive, at $370 on the sites I checked, but competing carbon fiber-helmets often range from $450 to $700.

For the price, the Kali Naza Carbon is an amazingly light, nimble and protective piece of helmet technology. Even if you look at the regular Naza models, starting at $150 USD, you're going to find a good deal on a light helmet with advanced protection at a solid price point accessible to all riders. Look out for Kali motorcycle helmets you may be seeing more around.

Kali Helmets for All Riders

Kali offers a full range of unisex, men's, women's and kids carbon-fiber street, cruiser and off-road motorcycle helmets. The company also delivers snow, powersport and bicycle helmets using their innovative construction techniques.

For more on Kali or to find a dealer, visit http://www.kaliprotectives.com

Find Kali on Facebook https://www.facebook.com/kaliprotectives or on Twitter https://twitter.com/KaliProtectives