Over 95% of hip fractures and 65% of traumatic brain injuries in older adults are caused by falls. These injuries lead to hospitalizations and a high risk of mortality. Although hip protector and headgear are considered as low-cost and effective solution in mitigating fall-related injuries, existing protectors are mainly developed in western countries and are bulky with thick foams, which make the protectors impermeable and less aesthetic. To address these limitations, our team developed the novel hip protector and headgear via the 3D-printing technique that can also customize the protectors based on the body profile of Asian older adults. Our 3D-printed hip protector and headgear pads demonstrate lightweight and breathable features. They also show high capability of impact force attenuation based on biomechanical tests. We envision that our innovative protectors would increase user acceptance and adherence, and offer better protection to older adults who are at high risk of falls.