Traditional sports helmets pose recycling challenges due to materials and assembly processes. FORO is a modular solution for sustainable sports headgear. Designed for production, maintenance, and end-of-life recycling, FORO overcomes the challenges of traditional helmets with difficult-to-recycle materials and complex assembly processes. The lattice structure, made of 3D-printed materials, replaces polystyrene foam, and adhesives are replaced with disassemble-friendly joints. The modular design provides a customized fit for all head sizes and shapes while extending the product's lifespan.