In the fast-paced world of NASCAR, drivers spend hours behind the wheel, battling not just their competitors but also extreme heat. Inside the car, temperatures climb fast, with engine heat, track reflection, and limited airflow making conditions even tougher. Staying cool isn’t just about comfort – it’s key to performance and safety. One of the most effective ways drivers combat the heat is with a helmet air system, which delivers a steady stream of air directly into the helmet. This helps regulate body temperature, prevent overheating, and fight fatigue, keeping drivers sharp and focused through the grueling hours on track.

Proforming LLC, founded by Chris Hladik in North Carolina, has been in business for 25 years, driven by the need to develop custom air channels that keep drivers cool. Proforming’s designs have been used in the prestigious Cup Series, Xfinity Series, IndyCar Series, and the DIRTcar and Sprint Car series. Their systems use either dedicated air conditioning or ambient air to help regulate a driver's temperature, improving comfort and performance on the track.

Air is fed through a channel, or ambient air from the car flows in to keep drivers cool

Air channels need to withstand harsh conditions and have good impact resistance, so material choice is key

Introducing the Multiplier was a game changer for Proforming’s workflow

NASCAR is built on ingenuity, engineering, and the drive to get the most out of every component – principles that shape Proforming’s design choices as well. Material choice is key because drivers race with a helmet and no windshield, leaving them exposed to dirt, rocks, mud, and debris flying into the car. Parts need to be impact- resistant and tough enough to withstand whatever the track throws at them. Just as important is having a manufacturing process that works smoothly with validated materials, making sure everything forms accurately.

Chris had started with vacuum forming and had refined the process to a high level, but there were still quality issues. While looking into pressure forming, he came across the Mayku Multiplier in a Google search. Seeing how it worked and how well it paired with the right materials was an eye-opener. When he received it and put it through its paces, he was all smiles for days.

I had it down pretty clean, but when you see the Mayku Multiplier do its job, it’s like, ‘wow, this is it.’

Chris Hladik, Proforming LLC

With the power of the Multiplier in his hands, Chris’s workflow now looks like this:

Idea. A request comes in from a customer, or Chris has an idea for a new air channel design.
Design. The concept takes shape in CAD, allowing Chris to refine the idea and simulate airflow performance to ensure it meets expectations.
3D print. When the concept is viable, a template is 3D printed in-house.
Pressure forming with the Multiplier. The material (in this case Holstex) is heated in the Multiplier, and pressure formed over the template in minutes, creating a durable, high-quality part.
Post processing. Excess material is trimmed, and rough edges are smoothed using abrasives.
Delivery. The customer has a new product in their hands within two weeks, ready for use.

A 3D printed form, which has been sanded for extra smoothness before forming

How the part looks after pressure forming on the Multiplier

Cutting excess material

Trimming excess material

Cleaning up rough edges using an abrasive rotary tool

A final part after forming, post processing, and cleaning

The final part perfectly conforms to the contours of the helmet thanks to the accuracy of the Multiplier

I’d say it’s changed the game. Stuff gets turned around pretty quick. It’s like, ‘Hey, can you do something?’ and bam – a couple of weeks later, they have a piece in their hand. It’s like, ‘whoa.’

Chris Hladik, Proforming LLC

Chris takes a long-term view of his work – as he puts it, “If you don’t look past the hood, sometimes you can’t see the road.” He is always refining his process, pushing for better results, and exploring new possibilities. With the Multiplier, he has only scratched the surface of what is possible. His ideas continue to evolve, shaping solutions that customers may not even realize they need. By forming the right material in the right way, he is creating products that set a new standard for performance and innovation.

Cooling Impact

  • Helmet air systems regulate driver temperature, preventing fatigue over grueling multi-hour races
  • Since NASCAR cockpits can reach 120 - 140°F (49 - 60°C), an efficient air channel makes a measurable difference in driver endurance and focus

Scalability

  • With the Multiplier, Chris can produce more parts faster without sacrificing quality, allowing for higher output and more customer orders

Durability under extreme conditions

  • The parts withstand high-speed impacts from dirt, rocks, and debris without failure
  • In NASCAR and IndyCar, cars can reach speeds over 200 mph, meaning any airborne debris hits with significant force – yet these formed ducts hold up

Precision and quality

  • The final product perfectly conforms to helmet contours, with a higher fit accuracy than standard vacuum forming
  • Pressure forming reduces inconsistencies in thickness, leading to more uniform, durable parts

Workflow efficiency

  • The process now consists of six key steps: idea, design, 3D printing, pressure forming, post-processing, and delivery
  • The Multiplier completes the forming step in minutes, compared to traditional vacuum forming, which can require multiple adjustments

Production speed

  • Chris can deliver a finished part within two weeks