The following articles will cover plastics helmets manufacturing production, various materials used to build motorcycle helmets and they all have different advantages. Helmets have several layers. The outer shell features a reinforced Styrofoam lined interior and a breathable padding that offers the perfect fit and moisture absorption. Because inner padding or foam layering tend to be more uniform across the helmet spectrum, these articles will focus on the commonly used materials for the exterior shell. The helmet is usually composed of a hard shell, a buffer layer, a comfortable cushion, a wearing device, and goggles, etc. The hard shell is mainly made of resin materials of PC, ABS, PC+ABS alloy materials, glass Fiber, and carbon fiber materials, etc.
What are safety helmet production process
Plastics helmets manufacturing will involve many parts of helmet manufacturing process and and helmet manufacturing machines. The helmet manufacturing process is mostly includes injection molding the child parts, buffing & sanding, painting & decals, attaching the visors & straps, multiple qualingly checks and then packing & shipping.
What are safety helmets made of?
The hard shell is mainly made of resin materials of PE, PC, ABS, PC+ABS alloy materials, glass Fiber, and carbon fiber materials, etc.
The goggles are mostly made of PC.
The buffer layer is made by foam normally.
The wearing device or pads is manufactured by PE for most.
China announced the policy of “One Helmet, One Belt” since this April. Zhejiang and Jiangsu released relevant regulations for riding safety. The regulations strongly pulled the helmet selling and production in China, and even has increased 3,500 new companies for this big market within one month.
Are helmets the same?
The helmets are not the same. There are many kinds of helmets, such as Full-face, Open face (3/4), Half, and Modular (flip-up) helmet and so on. In terms of safety, the Full face type is best, and the Half one is the worst. So the helmets is absolutely not the same, there are different safty helmets with different safty standards.
What are safety helmets standards?
DOT: Standards determined by the U.S. Department of Transportation. The DOT rating currently in effect is federal standard FMVSS 218, and any helmet with the DOT sticker should meet these standards (more on that later).
ECE: Standards determined by the Economic Commission for Europe. This multinational standard is used by more than 50 countries in Europe, and any helmet with this sticker must meet the current ECE 22.05 standard.
SNELL: Standards determined by the Snell Memorial Foundation. This is a voluntary testing procedure, and is only required by certain race bodies. The current standard is SNELL M2020 for street use.
FIM: A relatively new standard, the FIM rating is used for helmets that meet safety criteria established by motorcycling’s global racing organization for track use.
SHARP’s: The Safety Assessment and Rating Programme is a UK non-profit organisation that is part of The government.
SHARP’s impact test is the most complex of all standards. It uses seven helmets for impact tests. Six of the helmets are tested at 6 m/s, 7 m/s, and 8 m/s on the front, left, right, top, and back of the helmet with flat anvil and blunt anvil impact tests.The final helmet will be subjected to oblique friction impact tests at two points left and right.
The final impact results were calculated to determine the helmet star rating, with 5 stars as the highest rating and 1 star as the lowest rating.
What are helmet manufacturing machines
To produce the plastic helmet will need many kinds of helmet manufacturing machines. The most main parts is the plastic helmet shelles, it is made by an helmet injection molding machine. Which is the main plastics manufacturing machine. And the goggles and the wearing pads will be produced by the injection molding machine as well.
Plastic Helmet Parts Manufacturing Solutions
| Plastic Helmet Part Picture | Plastic Helmet Part Name | Helmet Parts Material | Helmet Parts Molding Cavity | Injection Molding Machine Size (Click to check details ) |
|---|---|---|---|---|
 |
Helmet Shell | ABS ABS+PC |
1 Cavity | 300 ton Injection Machine |
| 2 Cavity | 420 ton Injection Machine | |||
 |
Helmets Visors Helmets Goggles |
PC | 1 Cavity | 210 ton Injection Machine |
| 2 Cavity | 420 ton Molding Machine | |||
 |
Helmets Cushions | PE HD EPS |
1 Cavity | 210 ton Plastic IMM |
| 2 Cavity | 420 ton Plastic IMM | |||
 |
Wearing device Reflector |
PP PC |
16 Cavity | 170 ton Injection Machine |
| 32 Cavity | 420T Plastic Molding Machine | |||
| * We reserve the right to make changes as a result of further technical advantages. | ||||
Plastic helmet making production machines are mostly included below machines & auxiliary equipment:
1. Plastic helmet injection molding machine
2. Helmet injection mould
3. Material dryer or hopper dryer
4. Material Mixer
5. Materail auto-feeder ( vacuum feeder )
6. Product take out Auto-robot
7. Runner cut off robot
8. Product conveyor
The helmet production line will also need some factory basic machines and auxiliary equipment linke water tower, cooling chiller, air compressor, etc. These machines are the basic parts support of a plastic products manufacturing factory. Or called factory three basic infrastructure water, electric, air.
Plastic helmet shell mold Information ( Sample project )
| Helmet Shell Mold Description | Helmet Shell Mold Part Name | Motorcycle Helmet Specification | |||
|---|---|---|---|---|---|
| Product Description | Part Name | Motorcycle helmet | |||
| Part Material | ABS | ||||
| Part Size(MM) | 280*233*262 | ||||
| Mould Steel | A plate | S50C | |||
| B plate | S50C | ||||
| Cavity Insert | 2738 (HRC 34-38) | ||||
| Core Insert | 2738 (HRC 34-38) | ||||
| Slider Insert | 2738 (HRC 34-38) | ||||
| Ejector Plate | S50C | ||||
| Spare Parts | S50C | ||||
| Mould Description | Mould Size (L*W*H MM) | 570*620*764 | |||
| Mould Gross Weight (KG’s) | 1550 | ||||
| Mould Life Time (Shots) | 500,000 | ||||
| Mould Manufacturing Cycle | 45 days | ||||
| Surface Finish | polishing | ||||
| Runner Description | Coldrunner | ||||
| Injection Gate Type | Side gate | ||||
| Ejection System | Eject block | ||||
| Cycle Time (Second) | 50s | ||||
| Injection moulding machine | 420T Helmet Manufacturing Machine | ||||
| * We reserve the right to make changes as a result of further technical advantages. | |||||
Guanxin Plastic Machinery is one of the leading molding machines manufacturer in China. We offer our customers turnkey solutions for plastics products like helmets manufacturing plants machines. You can contact us if you have any ideas for making helmets.
