The 2026 NFL Helmet Laboratory Test Results have been released, and additive manufacturing has once again taken the top spot.
This annual test, conducted in partnership with the NFL Players Association (NFLPA), ranks helmets based on how well they reduce the force of head impacts. The Riddell Axiom 3D – manufactured using Carbon’s Digital Light Synthesis (DLS) technology – has held the number one position for three consecutive years. What’s more, five of the top ten helmets in the 2026 rankings (especially the top three) integrate Carbon’s 3D printing technology.
The rise of 3D-printed helmets in professional American football first drew attention several years ago. At the time, a growing number of players were choosing helmets with 3D-printed liners, and one important reason was that such helmets were rated “Guardian Cap Optional.” The NFL mandated the use of Guardian Caps – soft-shell covers worn over regular helmets to improve impact absorption – during preseason practices starting in 2022. However, many players complained about the comfort and weight of this extra protective gear, and were eager for a better solution.
3D printing technology filled that gap perfectly. This technology – especially Carbon’s DLS process – makes it possible to produce complex, customizable helmet liners and padding layers that improve both impact performance and wearing comfort. Today, several helmets using this technology have become top-tier products for head protection in professional football. Notably, many of these helmets are rated “Guardian Cap Optional,” and data show that they achieve equal or even better protection without the need for additional external padding.
Take the Riddell Axiom 3D as an example. This helmet features a 3D-printed lattice padding made from EPU 45 material, with custom‑tuned density to optimize impact absorption. Unlike traditional foam padding, the lattice structure is open‑cell based, offering significantly better ventilation and comfort.
The second-ranked helmet in the 2026 list is the VICIS ZERO2-R MATRIX ID 2025, which also incorporates padding components made with Carbon’s 3D printing technology. This helmet includes interchangeable, custom‑printed 3D padding, combined with VICIS’s own lattice structures and adjustable top comfort pads. The third‑place Schutt F7 Pro embeds DNA CORE 3D‑printed lattice structures, supported by Carbon, to enhance impact resistance. Also worth noting is the Riddell SpeedFlex True 3D, which made its first appearance in the top ten. As Carbon puts it, this helmet “perfectly combines the classic shell that players love with advanced 3D-printed lattice protection.”
The trend of replacing traditional foam with 3D printing – especially lattice structures – is becoming increasingly popular, for obvious reasons. In helmets, this technology allows manufacturers to more precisely tune key properties such as impact resistance, flexibility, and density, while also delivering better comfort through personalization and ventilation. An authoritative body with the level and influence of the NFL, consistently validating this reality with hard data, signals that 3D printing will continue to shape the future of helmet design – in football and beyond.
