The top-rated NFL helmet in 2026 is 3D printed

The results of the 2026 NFL helmet laboratory tests have been released and 3D printing is at the top. The annual tests, conducted in collaboration with the NFL Players Association, evaluate a range of helmets and rank them based on best reduction of head impact magnitude. For the third year in a row, the Riddell Axiom 3D helmet—made using Carbon’s Digital Light Synthesis (DLS)—has taken the first spot. Not only that: five of the top 10 helmets in 2026 (notably the top three) integrate 3D printed elements made using Carbon’s tech.

A couple of years ago, we covered an in-depth story about the rise of 3D printed helmets in professional American football. At the time, more and more players were opting for helmets with 3D printed liners, in large part because they were graded as “guardian-cap optional”. The guardian cap, made mandatory by the NFL in 2022 for pre-season practices, is soft-shelled headgear worn outside of a conventional helmet to improve impact absorption. Many players were resistant to this equipment upgrade, citing discomfort and weight, and a better solution was always needed.

Simultaneously, 3D printing has emerged as a solution to create complex and customizable padding and liners for helmets to improve impact absorption and comfort. The technology—in particular Carbon’s DLS—has been applied for a number of products, many of which are now among the top ranked for professional football when it comes to head injury protection. Notably, many of these have been listed as “guardian-cap optional” following data that shows they are as effective without the additional external padding.

The Riddell Axiom 3D, for instance, has been the NFL’s overall top ranked helmet based on lab testing for three consecutive years. The football helmet integrates a 3D printed lattice padding made from EPU 45, with tailored densities for optimized impact absorption. Unlike traditional foam pads, the lattice is based on an open-cell structure, which promotes better ventilation and comfort.

Second on the 2026 NFL list is the VICIS ZERO2-R MATRIX ID 2025, another helmet with padding components made using Carbon’s 3D printing tech. This helmet integrates custom-fit interchangeable 3D printed pads with a VICIS proprietary lattice as well as adjustable comfort top pads for fit and comfort. Number three is the Schutt F7 Pro, which integrate Carbon-enabled DNA CORE 3D printed lattice structures to improve impact performance. Also notable is a new 3D printed helmet that has made the top 10: the Riddell SpeedFlex True 3D, which, as Carbon says, “combines the iconic shell players love with advanced 3D printed lattice protection.”

Leveraging 3D printing—3D printed lattices in particular—for foam-replacement applications has become increasingly popular. It’s abundantly clear why. In the case of helmets, the technology gives manufacturers greater control over properties like impact resistance, flexibility, density, while also allowing for greater comfort through customization and ventilation. The continued data-backed recognition of this reality by an organization as major and known as the NFL suggests that the technology will continue to shape the future of helmet designs in football and beyond.