How Is A Motorcycle Helmet Manufactured? Detailed Steps from Start to Finish!
The unassuming motorcycle helmet that you take for granted every day is in fact the result of a painstaking manufacturing and assembly process which involves several steps and quality checks along the way to ensure that you get the best quality and safety when you are riding on the road.
We had the opportunity to check out how a modern motorcycle safety helmet is prepared and we thought you would appreciate knowing about it as much as we did. Let's take a look at all the steps that go into the process of designing and manufacturing a helmet before it reaches you.
Injection Molding the Child Parts
Multiple child parts go into the manufacturing of a motorcycle helmet. One of the important child parts is the EPS shell. The journey begins with tiny little beads of polystyrene which are expanded under pressure and heat to create what is commonly known in the industry as ‘foam’. In technical terms the polystyrene now becomes expanded polystyrene (EPS). The non-expanded beads are fed into an injection molding machine which puts out a shell of expanded polystyrene which is the internal shell of a motorcycle helmet. but this shell alone does not have the mechanical resistance to withstand high-impact forces which is why it is covered with a shell made out of ABS. Both of the cells are attached together using industrial adhesive into one combined external structure.
The visor that is used in helmets is also created in a similar process using transparent polyurethane beans which are pressed together under high pressure and temperature to produce clear visors or mirrored or rainbow-hued visors by adding different additives.
Buffing & Sanding
Once the outer shell is ready it proceeds to buffing and sanding station where the entire structure is polished and the joining marks left Behind by the injection molding machine is ground to a smooth surface using a special polishing machine and emery paper. This not only cleans the helmet surface of extra materials; it also prepares the shell for subsequent steps of painting the helmet. it must be noted that not all helmets are painted, and if that is the case the helmet proceeds today assembly line where the visors and straps are attached before packaging and shipping it.
Painting & Decals
After the buffing process, the helmet is completely cleaned of tiny materials and dust which might affect the overall result of the painting process. to ensure that there is no dust left on the surface of the helmet, multiple steps are done by the surface is rubbed with industrial alcohol and subjected to vacuum machines where even the tiniest dust particle is completely absorbed before the helmet proceeds to a hermetically sealed painting booth. Depending on the pre-decided color and design options the colors and mix by an expert and using a painting gun the surface is painted with a base coat and that is followed by another layer of the primary color. As soon as this process is complete, the helmet proceeds to the decal section of the Assembly line where expert workers paste decorative and colorful decals on the helmet and allow the helmet to set settle for a period of 3 to 4 hours (maximum of 8 hours) after which it goes back into the paint shop for a final layer of top coat.
Attaching the visors and straps
In a separate part of the manufacturing unit, workers design the straps and strapping mechanism along with other rivets and bushes that go into the helmet for securing the strap in place. Once the helmet comes out of the paint shop, workers in the assembly line merge the painted shell with the visor mechanism along with the strapping mechanism using multiple specialized tools for punching holes and attaching the straps security. Die-cut and Laser machines are used to precisely cut the pads and inner lining of the helmet with an accuracy of a few millimeters which ensure that the wearer gets the best comfort and safety while using the product.
Multiple quality checks
Each of the steps mentioned above passes through a stringent quality check at the end of the process to see whether the child parts meet regulatory requirements and internal quality parameters before it is passed on to the next section of the Assembly Line on the manufacturing process. Any part that does not meet the required quality parameters is discarded and recycled to reduce waste. Once the quality expert is completely convinced of the helmet meeting all necessary requirements and safety standards, the element becomes eligible to bear the ISI mark along with the Insignia of the company before it is sent forward to be packaged and shipped.
Packaging & Shipping
Finally, the finished product is packaged and shipped to multiple destinations across the world along with documentations to help the customer make the best use of the product
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2 июн 2022
