How Motorcycle Helmets Are Made?
Riding motorcycles can be a thrilling experience. But it is important to remember that safety is the top priority when it comes to enjoying this passion.
One of the most important pieces of safety gear is the motorcycle helmet. Every year, around 5,000 U.S. motorcyclists lose their lives in crashes. Many of these fatalities can be avoided when riders wear helmets. But have you ever wondered how these helmets are made?
The process of producing a motorcycle helmet requires intricate machinery, expert craftsmanship, and a lot of attention to detail. In this article, we will take a deeper look into how motorcycle helmets are made.
How Motorcycle Helmets Are Made?
The production process of motorcycle helmets involves several stages, each with its own unique steps and techniques. Here’s how motorcycle helmets are made:
Step 1: Creating the Outer Shell
The first step in making motorcycle helmets are creating the outer shell. The outer shell is designed to protect against impact and abrasion. It is usually made from materials such as carbon fiber, polycarbonate, or fiberglass, etc. These materials are known for their high strength and durability, making them ideal for helmet construction.
To create the outer shell, manufacturers use a process called injection molding. This involves injecting molten plastic into a mold containing the shape of the helmet. The mold is then cooled and removed to reveal the basic shape of the helmet.
Step 2: Making the Inner Liner
The next step is creating the inner liner, which is responsible for absorbing impact and providing cushioning to the head. The inner liner is made from expanded polystyrene (EPS) foam, which is known for its ability to compress and absorb energy upon impact.
To create the inner liner, manufacturers use a process called chemical foaming. This involves mixing small plastic beads with a blowing agent and heating them to create foam. The foam is then molded into the desired shape and density before being inserted into the helmet’s outer shell.
Step 3: Adding the Visor
The visor or face shield is an important part of a motorcycle helmet as it protects the rider’s face from debris, insects, and wind. The visor is usually made from polycarbonate material due to its high impact resistance and clarity.
To make the visor, manufacturers use a process called injection molding. They heat the polycarbonate material until it is pliable before injecting it into a mold containing the shape of the visor. Once cooled, the visor is trimmed and polished to ensure a clear view for the rider.
Step 4: Assembly
The final step in the manufacturing process is assembling all the components together. The inner liner is fitted into the outer shell, and the visor is attached using screws or snaps. The helmet’s straps, buckles, and ventilation systems are also added at this stage.
After assembly, the helmet is inspected for any defects or imperfections before being packaged and sent off for distribution.
Step 5: Quality Control
Quality control is an essential part of the helmet manufacturing process. Helmets undergo various tests to ensure they meet safety standards and provide adequate protection to the rider. These tests include impact testing, penetration testing, and chin strap retention testing.
Step 6: Certification
Once a helmet passes all the safety tests, it is certified for use by government agencies such as the Department of Transportation (DOT) or the European Union’s Economic Commission for Europe (ECE). These certifications ensure that the helmet meets minimum safety requirements and can be legally sold in the market.
That’s it! After going through all these steps, a motorcycle helmet is ready to be worn and protects riders on the road.
What Materials Are Motorcycle Helmets Made Of?
Besides knowing how helmets are made, it is also essential to understand the different materials used in their construction. Each material offers specific properties that contribute to a helmet’s overall performance and safety.
1. Polycarbonate
Polycarbonate helmets are incredibly lightweight and versatile and are usually the preferred choice for novice riders. They’re shaped into a single shell that is designed to resist impact and provide maximum protection. Polycarbonate helmets are not the most expensive option and are preferred by riders who are still trying to figure out their ideal helmets. They function by absorbing shock by the compression of their shell. The polycarbonate used now is of high quality and thickness.
2. Fiberglass
Fiberglass motorcycle helmets are designed with a shell made of fiberglass, which makes them lightweight, strong, and highly resistant to cracking and chippings. They provide a considerable amount of strength, making it a perfect option for almost any rider, from cruising down the freeway to participating in stunts. Fiberglass motorcycle helmets are also usually an affordable option if a rider is looking for affordable protection but wants a material that is guaranteed to last.
3. Kevlar
Kevlar provides a good alternative to carbon fiber and fiberglass. Kevlar is lightweight and incredibly sturdy. It has a fantastic impact resistance capability, making it a great option for riders who prioritize safety and prefer to ride in demanding conditions. Kevlar is also affordable, a perfect option for riders looking for something durable whilst still looking for a cheaper alternative.
4. Carbon Fiber
Carbon Fiber helmets are the pinnacle of helmet technology. They are designed to be incredibly light, durable, and robust, keeping riders safe whilst providing superb aerodynamics. Carbon fiber provides excellent durability and comes with a superior strength-to-weight ratio, making it the best option for racers. Carbon fiber is also expensive, requiring an extensive manufacturing process that requires a lot of time and effort.
5. Synthetic Reinforced Shell
Synthetic-reinforced shells provide exceptional strength. It’s a combination of two materials, Coolmax fiber and thermoplastics. Synthetic-reinforced shells provide fantastic resilience and stability. They’re a lot more durable and robust than polycarbonate helmets, but they’re also more expensive.
6. Composite Materials
Composites are made up of various materials such as carbon fiber, Kevlar, and fiberglass. They have a superior strength-to-weight ratio, which makes them extremely durable, lightweight, and less resistant to cracks. These materials aren’t as common as polycarbonate helmets but provide better depth protection. They are manufactured using several layers of materials and then bonded together under pressure with heat-activated resin. Due to the extensive manufacturing process, they’re more expensive than a polycarbonate helmet.
How Are Motorcycle Helmets Tested?
To ensure the safety and effectiveness of motorcycle helmets, they undergo various tests before being certified for use. These tests aim to replicate real-life scenarios and assess how well a helmet protects the rider in different situations.
1. Impact Testing
One of the most crucial tests that a motorcycle helmet undergoes is the impact test. The impact test is conducted by dropping a weighted head form from various heights and angles to replicate real-life crash scenarios. The helmet is then examined for the impact’s performance on its shell, liner, and retention system. The test aims to ensure the helmet can withstand and absorb the energy of a collision. Helmets are also tested for penetration resistance, where a sharp object is dropped onto the helmet to see if it punctures or cracks.
2. Chin Strap Retention Testing
Chin strap retention testing ensures that the chin strap can withstand a certain amount of force without breaking or detaching from the helmet. This test is crucial as a properly secured helmet can significantly reduce the risk of a head injury in an accident.
3. Shell Rigidity Testing
Shell rigidity testing assesses the strength and resistance of a helmet’s outer shell to deformation. Helmets with a strong and rigid shell can better absorb impact, providing more protection to the rider’s head.
4. Field of Vision Testing
Field of vision testing is conducted to ensure that a helmet allows the rider to have a clear and unobstructed view of their surroundings. This test helps prevent accidents caused by limited visibility.
5. Comfort Testing
Comfort testing is done to assess how comfortable a helmet is for prolonged use. Helmets should not cause any discomfort or pain while being worn, as this can distract the rider and potentially cause accidents.
Choosing the Right Motorcycle Helmet (Some Factors)
After all, the most essential part of a helmet is ensuring that it fits in as snugly and comfortably as possible. Here’s a quick guide to help you choose the right motorcycle helmet:
Fit and Comfort
A helmet that fits well and is comfortable to wear is crucial for a rider’s safety. The helmet should be snug but not too tight, with no pressure points or discomfort. A properly fitting helmet will stay in place during an accident, providing the necessary protection.
Safety Standards
Always ensure that the helmet you choose meets safety standards set by organizations such as DOT (Department of Transportation) or ECE (Economic Commission for Europe). These standards ensure that the helmet has undergone rigorous testing and can provide adequate protection in case of an accident.
Helmet Type
There are various types of motorcycle helmets available, such as open face, full face, half helmets and modular,. Each type offers a different level of protection and features, so it’s essential to choose one that suits your riding style and needs.
Material
The material of a helmet plays a crucial role in its safety and durability. As discussed earlier, there are different materials used in the production of motorcycle helmets, each with its own pros and cons. Consider your riding style, budget, and preferences when choosing the right material for your helmet.
Conclusion
The process of making motorcycle helmets requires the finest attention to detail and craftsmanship. All components must be carefully designed and constructed to ensure maximum safety for the wearer.
Thanks to modern materials and manufacturing methods, helmets have become lighter and stronger, yet still able to provide excellent protection. For riders who take their safety seriously, investing in a good quality helmet is essential.
By understanding how motorcycle helmets are made, we can have a greater appreciation for the technology and expertise that goes into keeping us safe on the road.