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BikeRadar afresh visited Kask’s assembly ability in Italy area we abstruse how a avant-garde in-mould helmet is produced.

The exact model, whose assembly we shadowed, was Kask’s continued active and acknowledged Protone alley lid. It’s this process, and slight variations of it, that sees Kask aftermath about 200,000 helmets a year in Italy.

You can anticipate of a avant-garde in-mould helmet as actuality fabricated of two key parts: the carapace and the liner. We bang off with the assembly of the carapace below.

KASK’s Protone starts out activity as a distinct polycarbonate sheet

The carapace of our helmet starts off activity as a distinct polycarbonate sheet. One that is again loaded into a ample press machine.

Paint is again added by duke into the apparatus appliance pre-mixed colours.

Paint is again activated appliance a ample press machine

Multiple layers of acrylic are generally acclimated to accomplish the actual finish, with assertive fluoro colours acute this action to be completed seven times!

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Each band of acrylic takes about 40 account to dry.

Once the actual accomplishment is accomplished the polycarbonate is again accessible for exhaustion forming

The bedding can again be loaded into the manufacturer’s exhaustion basic apparatus area the polycarbonate is acrimonious to about 90 degrees afore it is fatigued over a helmet-shaped mould as air is bound removed.

The bedding are loaded in abode at the exhaustion basic machine, below them are two helmet-shaped moulds

Heat is activated and then…

The acrimonious polycarbonate is fatigued over a helmet-shaped mould

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A cogent allotment of the helmet’s carapace is now visible

The aloft area of polycarbonate area — allotment of the carapace — charge again be cut from the balance actual that surrounds it.

The vacuum-formed carapace sections charge again be aerial from the moulds and akin from the sheet

Other sections of the carapace are produced in the aforementioned way but crave added finishing.

These genitalia are placed assimilate a board mould while a pre-programmed CNC apparatus makes attention cuts to the artificial for any vents or edges.

Please don’t be abashed by the altering colours here, the branch handles abounding altered colour options!

More intricate genitalia are accomplished by a CNC cutter

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Suddenly things alpha to attending a accomplished lot added helmet-like.

Shell apparatus are again affection inspected afore actuality packaged in alertness for the aing accomplishment process

The helmet’s liner is fabricated by accretion granules of EPS cream aural a mould. The delicate cream expands back it is subjected to a aggregate of beef and pressure.

The EPS cream arrives in delicate anatomy afore it expands into baby spheres with the appliance of beef and heat

The broadcast polystyrene (EPS) chaplet access in delicate anatomy and are stored in all-inclusive vats at one ancillary of the factory, and are disconnected into altered types and densities.

A all-inclusive arrangement of vats accommodate cream of assorted types and densities

Steam is activated to the sherbet-like polystyrene, which again causes anniversary one to aggrandize significantly. After a few hours of blow these chaplet accept the actual appearance and are accessible for the aing footfall of the process.

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The apparatus we saw beforehand are again loaded into a apparatus alongside these added artificial parts

The carapace we fabricated beforehand is again placed into a mould forth with assorted pre-made artificial components. These artificial inserts anatomy allotment of a structurally cogent ashen anatomy aural the helmet’s liner and are generally all-important to accumulate helmets with ample vents from amid in case of an impact.

Unfortunately, what takes abode aing I wasn’t accustomed to photograph, but it’s best declared as authoritative a big helmet sandwich.

Two opposing abandon of a ample and alarming apparatus are loaded with what will finer become the top and basal of the helmet. Then, already all animal limbs are out of the way, the apparatus comes calm in a way that’s evocative of the debris compactor arena in the aboriginal Star Wars film.

A few affable curtains with a mallet is all that is appropriate to abstracted the helmet from its mould

Lots of hissing and flicking dials affirm that the polystyrene chaplet are authoritative their way into the now bankrupt mould.

Approximately six account after and the behindhand abstracted already more, abrogation a accumulated carapace and liner in the anatomy of a helmet that is actual about complete.

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Two behindhand and abounding apparatus are accumulated as acrimonious EPS chaplet agglutinate calm to anatomy the helmet’s shape

No straps or stickers yet but the Protone is about complete

The helmet can now be acclaim prised from its close mould, and is again kept in a dehumidified ambiance to aish any moisture.

Finishing capacity and final affection inspections are again all that is appropriate afore the helmets become aggregation stock

The lids are again alien to addition ability area the on strap, assimilation system, added and stickers are applied.

Finally, affection ascendancy checks are completed afore the helmet makes its way advanced through Kask’s benefactor networks and eventually assimilate the active of riders. 

Kask produces about 200,000 helmets a year

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