The Complex Process of skate helmet manufacturing – Creating a Safe and Stylish Skate Helmet
Skate helmets undergo a complex manufacturing process to provide protection while still being lightweight, comfortable and stylish.Here are the main steps:
1. Design
The designer creates computer drawings of the helmet, determining the shape, vents, fit and finish. Complex designs with interchangeable parts allow for customization.
2. Material Selection
Materials like expanded polystyrene (EPS) foam, polycarbonate, ABS plastics and fibers are selected based on their density, strength and weight properties.
3. Mold Creation
Custom molds are created using CNC machines and molding techniques to precisely match the helmet design.
4. Molding and Forming
The EPS beads are expanded and molded to form the inner liner shape. The outer shell layers are molded or vacuum formed using polycarbonate or ABS plastic sheets.
5. Assembly
The various components like the liner, shell and fittings are assembled together to form the complete helmet structure.
6. Finishing
Surfaces are sanded, holes are cut for vents and straps, and the helmet is primed and painted to achieve the desired finish.
7. Testing
The helmets are put through rigorous testing to certify that they meet global standards for impact absorption, strength and retention systems.
8. Packaging and Distribution
After passing all tests, the helmets are cleaned, inspected, packaged and labeled for sale and distribution.
By understanding the manufacturing steps behind them, you can better appreciate the thought, materials and safety engineering that go into creating the skate helmets that protect you.