KAV Consolidation in WNY Nearly Complete

Now that it's bid farewell to its Silicon Valley birthplace, KAV Helmets continues consolidating and preparing for growth in its Buffalo operations.

KAV, which uses 3D printing technology to create custom aerodynamic helmets designed to reduce brain injuries, is in the process of consolidating its manufacturing operations into the Barcalo building on Louisiana Street.

CEO Whitman Kwok touted KAV’s production process as a “one-of-a-kind advanced manufacturing platform in the heart of Buffalo.” The key to KAV's mini-fab manufacturing process, he said, is the ability to produce a large amount of product with a small number of inputs.

While KAV plans to stay in the protective gear space, Kwok said products beyond helmets are expected to be released by January.

The local facility became operational in May. It has gone so smoothly that Kwok determined continuing to run a duplicate plant in Redwood City, California, no longer made sense.

“This facility has done so well that we are actually not only building this factory here, but also consolidating production capabilities,” Kwok said, noting that the company saw double-digit month-over-month revenue growth when the facility came online.

The consolidation, Kwok said, was also driven by Buffalo’s talent pool and vibrant cycling community.

Equipment started being shipped from California to Buffalo in August, and those employed at the Silicon Valley location have been offered jobs in Buffalo. If those employees opt against moving, Kwok said, they can still work remotely.

An uptick in sales since May will also allow KAV to continue investing in facilities and people. He said the company recently hired two employees on the production side and more are likely to come.

KAV employs between 10 to 20 people. Kwok declined to provide an exact total, citing “competitive reasons.”

“We will continue to hire, but I don’t want to get too far ahead of ourselves. Obviously, it depends on revenue. We have a bunch of new products that are coming out, which will drive additional growth,” he said.