“For safety for all, wear a helmet in case you fall.” But, from what type of material helmets are made of for keeping us safe? How does the helmet work to protect us from any kind of injury?
Are these types of questions coming into your mind? Then do not worry, because this article will answer all of the queries. This informational write-up will serve you full-fledged knowledge regarding manufacturing, working, followed by important facts about the helmet. And, for gathering all the information you have to read this article till the end. So, let us start without wasting any minute.
How Bicycle Helmets are made?
Millions of trillions of bike helmets are produced in our country. The process of making a bicycle helmet is comparatively simple. But before starting the manufacturing process the sketches of the design of helmets has to be finalized with the help of CAD software and then foam prototypes have to be prepared for testing the looks and fitting.
The following basic building method is commonly adopted by bike helmet companies and has three important components:
- A hard outer layer or shell for holding it all intact.
- A soluble inner layer for energy absorption during an accident or crash.
- Assorted belts and padding for placing the helmet on your head firmly and safely.
The Outer Hard Layer
There are many ways of making helmet frames, and selecting one depends on the end product’s material and production. A helmet frame made up of blank sheet on a vacuum coating unit of PC (Polycarbonate). For designing and forming the shells of helmets, a special vacuum forming machine is used. To obtain its final look, the blank layer of PC heated up and then firmly vacuumed over the instrument.
However, other times helmet frames, are constructed with the same quality of plastic shaping machines that are used for making phone cases or toothbrushes. Moreover, skate-style helmets are made up of thick ABS plastic shells.
Painting of Decals and Shells
The next step is to paint the manufactured shells. The painting method is a mixture of automated robots for spray painting and humans for loading/unloading and adding the final touches.
Some frames have more complex designs that are added until they are shaped on the raw material sheets. When they are plain, these designs appear distorted but become evenly correct after molded into a helmet frame.
Helmet Straps
The next components of a helmet are its straps. All the straps are mostly similar in appearance but different in terms of fabric, weave, subtle finish, and other such factors. Generally, these straps are made up of polypropylene or nylon. Instead of adding the straps before the molding process then glued up to the liner before fixing it to the inner frame. The molding process can damage the webbing of the straps.
After, assembling the straps as per the design of the helmet shell, the next step is to fix the buckles to the straps. Currently, buckles are of plastic or nylon with a side pinch. Although some high-quality BMX helmets used D-ring buckles that have to be fixed with the help of thread.
Interior and Assembly
The interior depends on the type of helmets. If the helmets are manufactured with a ring fit system then it will be equipped with ring adjustments inside the helmet. Moreover, those that come with fitting pads get wire mounts affixed with the glue and then add the pads. Even some of the helmets have plastic or cloth liners or some of the BMX helmets have complicated liners that are easily detachable for cleaning.
The most important step is assembling all the components. This step requires hand labors for gluing or taping up the components. However, gluing or taping also depends on the design of the helmet.
Final Touches or Finishing
The brand logos are fixed by silk-screened or pad-printed on the newly manufactured helmets. Even, text stickers have to be affixed inside the helmet. Moreover, price and warranty tags need to be attached before boxing the helmet.
Extra accessories
Most of the helmets come with extra accessories and that depends on the brand and model of the helmet. Many of the helmets come with light mounts, detachable visors, light speakers for sound, earmuffs, etc.
How are motorcycle helmets made?
The variety of motorcycle or bike helmets like Full face, 3/4th, motocross, flip-up, half face, novelty face helmets are readily available in the markets. The process of manufacturing motorcycle helmets is quite similar to bicycle helmets. The following are the steps involved in the manufacturing process of BKS helmets. Let’s have a quick look at them.
- With the help of a computer layout of helmets have to be designed.
- After that Prototypes, are formed using foam made from polyurethane. Moreover, for mass manufacturing of helmet shells, metal moulds are constructed.
- Polycarbonate granules are melted and then used to produce the helmet’s outer hard layer. outer hard layer.
- The casing is polished by an automated robot and then it has to be painted. However, an unpainted helmet must have stickers meant to apply.
- On either side of the helmet, pivot systems are fitted and shock absorbing helmet liners, together with padding, are manufactured and incorporated.
- A clear face shield and chin guard are fitted to the helmet.
- The last important step is testing of the helmet and approval after manufacturing. And, now your helmet is ready to protect you from any kind of crash or road injury.
Some Interesting Facts about Helmets
A helmet is essential for every rider. But, do we know the facts about the motorcycle helmet we use? Let’s have a look at the below-listed facts for your reference.
- Do you know almost 98 countries in the world have a comprehensive helmet law that covers users, roads, engine types and apply helmet standards as well.
- However, 155 countries around the world have comprehensive motorcycle helmet laws that cover passengers and drivers for all types of roads and types of engines.
- Even, 98 countries follow national or international standards of motorcycle helmet.
- If you wear a helmet then you can reduce the risk of severe injuries can be reduced by 60%.
- In an unfortunate accident, a rider who is not wearing a helmet is 40 percent more likely to be killed.
- Average hospital treatment expenses would be 3-4 times higher following an accident if you are not wearing an accident.
Final Words
There is no denial in the fact, that wearing a helmet can reduce the risk of severe injuries and death in a road crash. However, while selecting an appropriate helmet for your safety, you should be aware of the facts about the helmet and the steps involved in the manufacturing of helmets.
I hope after reading this article, you will get an idea about the facts and production process of bicycle and bike helmets. So, in the end, we are wishing you a safe ride towards your destination.