Helmet manufacturing process

  • Author :
  • TATA AIG Team
  • Published on :
  • 01/12/2023

Many times, we are asked to wear a helmet while driving a motorcycle. People on construction sites are mandated to wear helmets. Wearing a helmet keeps us safe from any accident.

It safeguards the head, neck, eyes, teeth, face, etc., from severe fracture and thus prevents any serious injury. The impact of any accident is significantly less when you have your helmet on.

The statistics show that a helmet reduces around 70% risk of any head injury. While it is that important, let us understand how helmet manufacturer companies make this safety gear for bike riders. Within this blog, we will explore the components of helmets and the helmet manufacturing process.

So keep reading!

What are the Components of a Helmet?

The motorcycle helmet manufacturers keep the following 3 essential components in every helmet:

The Shell

It is the hard part that is present in the outer layer of the helmet. It holds all the components of the helmet together. It acts as a protective shield to the foam liner.

The helmet’s shell is prepared of a mixture of various materials depending upon what type of helmet is being produced. Its job is to protect your head from bumps and sharp objects. It is usually made out of tough materials like fibreglass or polycarbonate.

MIPS ( Multi-Impact Protection System)

The MIPS protects and acts like a protective shield to the brain. Along with the helmet’s foam liner, it recreates the human skull and the fluid underneath it. Right under the outer shell of the helmet, there is a thin layer of spongy material.

This is often made of polystyrene, which is the same material used in coffee cups but is thicker than it. Its main job is to reduce the impact of shocks or jerks in the event of you falling off your scooter or bike. It tries to minimise the impact reaching the actual brain during accidents.

The Inner Part

The inner part consists of the foam liner of the helmet. It is a soft part that covers the head and lies underneath the Multi-Impact Protection System and the outer shell.

This is considered as one of the most important parts of the helmet as it not only comforts the head but also handles the energy of the crash. Its main job is to provide you comfort and not cause irritation to your skin.

These are the 3 major parts of the helmet. Other than this, we all have seen the accessories attached to the helmet.

Other Accessories

Other accessories include the clips, buckles, and straps of the helmet. They are used for comfort wearing and proper adjustments of the helmet. These accessories are attached at the end of the helmet production process.

Helmet Production Process

The helmet manufacturing process, especially for motorcycles or bikes, involves the usage of a variety of raw materials or several processes. Here is a simple explanation of how a helmet is manufactured:

1. Design and Prototyping

This is the first step of the manufacturing process in which the shape, size, and features of the helmet are conceptualised. This could also involve designing a prototype for testing.

2. Injection Molding

Various parts of the helmet are moulded in this step. Parts and components like the visor and the foam are produced in this step to create what we call an inner shell.

First, small beads of polystyrene are expanded using the principles of pressure and heat to create the foam. The outer shell is also created.

3. Creating the EPS liner and Foam

The EPS foam is moulded and expanded into a precise shape that fits inside the outer shell of the helmet.

The foam used for padding is cut and shaped to fit inside the helmet. This is done to facilitate the comfort of padding inside the helmet.

4. Buffing and Sanding

After preparing the outer shell, the shell is sent for polishing. If there are any marks left in the injection and moulding process, they are cleaned and rubbed with a special type of polishing paper to produce a smooth surface.

The buffing and sanding process prepares the helmet for further processing if painting the helmet is involved.

5. Helmet Painting and Dust Vacuum

In this process, the helmet is wiped and cleaned to prevent any tiny materials or dust particles from preventing the painting process of the helmet. Most of the time graphics are painted in the case of the motorcycle helmet manufacturing process.

6. Attaching Accessories

In a separate unit of the helmet manufacturing factory, the workers design the straps and the mechanism to lock the helmet and all the other smaller parts that get attached to the helmet.

Once the helmet is painted, the workers start assembling the helmet and attach the visor, the straps, and all the other smaller parts with the help of different types of specialised tools.

The pads and the inner lining are fit using advanced technology like laser cut machines to maintain precision and comfort.

7. Quality Checks

In this stage, completed helmets undergo quality control checks. They are tested for sharp strength, impact resistance, and overall durability to ensure safety.

The helmet passes various quality checks to see if it meets the regulatory and safety requirements.

8. Packaging and Distribution**

Once the helmet passes all the tests, they are packed and shipped to the distributors or retailers. And later to the ultimate customers for their usage.

This process may slightly differ depending on the manufacturer and type of helmet. The bike helmet manufacturing process is a little different from those of other helmets.

To Encapsulate

Although a little uncomfortable, helmets act as a safety while you are on your way on a two-wheeler. When on a long ride and in the traffic, always wear your helmet.

However, a helmet will save you from physical injury, but what about the financial damage caused to your bike in case of an accident? A comprehensive insurance for two-wheelers is the best choice to take care of that.

Tata AIG helps you in simplifying the insurance purchase with a bike insurance calculator. With this facility, the price of two-wheeler insurance can easily be calculated according to your convenience and requirements. With good insurance for two-wheelers and a helmet on, you can be carefree with your safety on the roads.

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