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Helmet manufacturing process: From design to production

Team AckoJan 17, 2024

Helmets are essential personal protective equipment used in various industries and activities to protect the head from injury. From construction workers to bike riders, helmets have significantly reduced the risk of head injuries and fatalities. But have you ever thought about how helmet manufacturing works? If you are interested in the answer, read ahead, as in this article, we will take a deep dive into the helmet manufacturing process and explore the various steps involved in creating these lifesaving pieces of equipment.




Essential parts and process of helmet manufacturing

From the raw materials to the finished product, many steps are involved in creating these crucial pieces of personal protective equipment. Here is a step-by-step guide to the helmet manufacturing process.

Step 1: Gathering raw materials

The first step in helmet manufacturing is gathering the raw materials used to create the finished product. This typically includes materials like polycarbonate plastic for the exterior shell, foam for the inner padding, and nylon or other durable materials for the straps and buckles. These materials are usually sourced from suppliers and transported to the helmet manufacturing facility.

Step 2: Design and development

The next step is design and development. This is where engineers and designers work together to create a helmet prototype, considering important aspects such as weight, fit, and ventilation. They may also consider the end user's specific needs, such as whether the helmet is intended for athletes, construction workers, or someone else.

Step 3: Moulding and shaping

Once the design has been finalised, it's time to start moulding and shaping the raw materials into the various parts of the helmet. This is typically done using injection moulding, in which the raw materials are heated to a high temperature and then injected into a mould that has been shaped to match the desired helmet design. The mould is cooled, and the resulting parts are removed and assembled into a complete helmet.

Step 4: Assembling the Helmet

The next step is assembling the helmet's various parts. This typically involves attaching the exterior shell to the inner padding, attaching the straps and buckles, and adding any additional features like ventilation holes or reflectors.

Step 5: Testing and quality control

Before a helmet is ready to be shipped off to customers, it must undergo rigorous testing to ensure it meets the necessary safety standards. This may include impact testing, in which the helmet is subjected to simulated collisions to see how it performs. Other types of tests are also performed to ensure that it fits properly and provides sufficient ventilation. Once the helmet has passed all these tests, it is considered ready for sale.

What are helmet standards?

Helmet standards are guidelines that are used to ensure that helmet products are safe and effective. These standards are established by Indian Government organisations such as the Indian Standard Institute (ISI), now known as the Bureau of Indian Standards. Many other international organisations issue safety ratings for helmets, such as the US Department of Transport (DOT), SNELL, ECE, SHARP, and more.

These safety ratings are designed to test the performance of helmet products in a variety of different conditions, including impact resistance, penetration resistance, retention system strength, and other factors. In order to meet these standards, helmet manufacturers must subject their products to a series of tests to ensure that they are safe and effective.

Safety first

As you can see, many steps are involved in creating this essential piece of protective equipment. But all that hard work and attention to detail is worth it, as helmet use has significantly reduced the risk of head injuries and fatalities. So the next time you plan on buying a helmet, ensure you buy the safest model with the right certification from an authorised organisation.

Frequently Asked Questions (FAQs)

Here are the answers to some common questions about the helmet manufacturing process.


How are helmet liners made?

Helmet liners are typically made by injecting polystyrene foam into a mould. The polystyrene foam is heated until it becomes molten and is injected into the mould under high pressure. The mould is cooled, and the helmet liner is removed.

Can my bike insurance claim be rejected for not wearing a helmet?

Your insurance claims could be rejected for not wearing a helmet, which is considered negligent riding and illegal.

What kind of helmet is safe while riding a two-wheeler?

Wear an ISI-certified helmet for a safe ride.

How are helmet sizes determined?

Helmet sizes are typically determined by measuring the circumference of the head just above the eyebrows. Different helmet brands and models may have slightly different size charts, so it is crucial to refer to the specific size chart for the helmet you are interested in.

How are helmet safety ratings determined?

Helmet safety ratings are typically determined by testing organisations such as the BIS (formerly ISI), the US Department of Transportation (DOT), or the Economic Commission for Europe (ECE). These organisations have specific testing protocols that helmet manufacturers must follow to receive a safety rating. The tests simulate different types of impacts and measure the helmet's ability to protect the head and reduce the risk of injury.

How long does it take to make a helmet?

The amount of time it takes to make a helmet can vary depending on the complexity of the design and the production volume. It can generally take a few days to several weeks to complete the entire process.

Disclaimer: The content on this page is generic and shared only for informational and explanatory purposes. It is based on industry experience and several secondary sources on the internet, and is subject to changes. Please go through the applicable policy wordings for updated ACKO-centric content, and before making any insurance-related decisions.


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