Designed to exacting specifications, a properly made bicycle helmet helps protect a cyclist from serious injury in the event of a fall. Constructed of solid, impact resistant materials, the helmet is still light and comfortable to wear. Manufacturers also make helmets aesthetically pleasing in a wide range of colors and designs. The assembly process creates a product that provides safety and style to cyclists of all ages.
Initial Design
Engineers and designers first create the form of the helmet in a computer modeling system. This system produces a three-dimensional view and defines all of the specifications for the helmet. The engineers also ensure the helmet design meets safety standards. Graphic designers then produce artwork that will adorn the outer shell of the helmet. Molds are then manufactured to form the outer shell and the foam interior of the helmet.
Outer Shell
The outer begins as a flat sheet of plastic. A worker inserts the plastic sheet into a molding machine, which first heats the plastic to soften it, making the sheet easy to form. The machine then presses a mold in the shape of the outer shell up into the hot plastic sheet. A vacuum draws the plastic down, forming it to the mold until it is cool. The plastic sets in the shape of the mold. Another worker then cuts preformed air circulation holes in the shell using a heated wire. The worker then trims any excess plastic from the edge of the shell and sands the edges to even them.
Foam Interior
To manufacture the foam interior of the helmet, polystyrene granules enter an expander machine to form foam polystyrene beads. The beads then move to a high-pressure mold, filling each cavity within the helmet mold pattern. The beads are then put under pressure and steam heat to bond them together, then sprayed with cool water to set them into shape. A worker then uses a heat iron to cut any vent holes into the foam interior.
Adjustment Pads
Foam adjustment pads that fit into the helmet are produced next. A worker places preformed metal pattern dies onto a sheet of foam-backed fabric. A large vertical press bears down on the die to cut the fabric to the proper shape. Another worker applies Velcro strips to the pads and positions them inside the foam interior of the helmet.
Final Assembly
The helmet straps are then constructed of flat nylon webbing and plastic snap fittings. Once completed, a worker securely installs the helmet straps into the foam interior. The outer shell and the foam interior now come together to form the helmet. A worker places the outer shell to the foam interior and secures them with a band of adhesive tape.
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