Carbon Fiber & Composite Tooling

Aurora can also support tooling for carbon fiber and composite helmet shells and custom composite products.

Depending on the project, our team can support:

• Composite mold engineering
• CNC-machined mold development
• Shell geometry development
• Component-interface engineering
• Edge and trim definition
• Prototype molds
• Production tooling
• Mold trials and production optimization

This capability can be integrated with Aurora’s composite manufacturing and helmet-development programs.

Tooling for Integrated EPS Components

One of Aurora’s specialized capabilities is developing EPS products that incorporate molded-in components or mechanisms.

Examples may include:

• Plastic reinforcement frames
• Adjustment components
• Structural inserts
• Mounting plates
• Mechanical interfaces
• Functional plastic parts

Aurora can engineer both the component and the EPS tooling to help achieve:

Accurate Positioning + Clean Interface + Proper EPS Formation + Reliable Assembly

This is particularly important when the customer wants a plastic mechanism to sit closely and cleanly inside the EPS structure with minimal visible gaps.

Mold Flow Analysis

For suitable injection-molded components, Aurora can perform mold flow analysis before finalizing production tooling.

Our engineering team can evaluate factors such as:

• Material filling
• Gate position
• Runner configuration
• Multiple-gate balance
• Weld-line locations
• Air traps
• Injection pressure
• Packing
• Cooling
• Shrinkage
• Warpage risk
• Sink risk

This is especially valuable for complex or thin interconnected components such as fit systems and internal reinforcement structures.

The results can be used to improve the mold design before steel is cut.

Mold Design & Engineering

Aurora can develop production mold designs based on the product’s manufacturing requirements.

Depending on the tooling type, our engineers can evaluate:

• Core and cavity structure
• Parting lines
• Gates and runners
• Draft angles
• Slides and lifters
• Undercuts
• Venting
• Cooling
• Steam distribution for EPS tooling
• Ejection
• Shrinkage
• Critical dimensions
• Component interfaces
• Insert positioning
• Mold maintenance requirements

Because Aurora also manufactures the final products, tooling decisions can be made with the actual production process and final assembly in mind.

Prototype & Development Tooling

Not every project should move directly into full production tooling.

Aurora can develop prototype or development tooling where appropriate to help customers evaluate:

• Product geometry
• Fit
• Component interfaces
• Assembly
• Manufacturing feasibility
• Functional mechanisms
• Material behavior

This can help identify engineering issues before larger tooling investments are made.

Mold Trial & Sample Evaluation

Aurora’s tooling capability continues after CNC machining is completed.

We can perform mold trials and sample evaluation to determine how the actual material behaves in the finished tool.

During mold trials, our teams can evaluate:

• Product dimensions
• Surface quality
• Material filling
• Warpage
• Shrinkage
• Assembly fit
• Component alignment
• Functional movement
• EPS formation
• Insert positioning
• Cosmetic appearance

The first molded part is not automatically considered the finished result.

It becomes engineering feedback.

Tooling Modification & Correction

If the first mold trial identifies an issue, Aurora can evaluate the root cause and perform the necessary tooling corrections.

Depending on the project, this may involve:

• Dimensional correction
• Cavity modification
• Gate adjustment
• Venting improvement
• Fit correction
• Insert-position adjustment
• Surface modification
• Assembly-interface correction
• EPS mold optimization

The process may continue through additional trials until the production-intent product reaches the approved condition.

Trial → Measure → Analyze → Correct → Retest

is a normal part of professional tooling development.

Jigs, Fixtures & Assembly Tooling

Aurora can also develop supporting manufacturing tools required after the main component has been molded.

These may include:

• Assembly jigs
• Positioning fixtures
• Trimming fixtures
• Drilling fixtures
• Bonding fixtures
• Component-installation tools
• Inspection gauges
• Quality-control fixtures

These tools can help improve repeatability when the helmet contains multiple components that need to be positioned accurately during production.

Multi-Size Helmet Tooling Programs

A complete helmet program may require much more than one mold.

Aurora can help plan tooling across an entire size range.

For example:

Small / Medium / Large

may require combinations of:

• EPS molds
• PC forming tools
• Shell molds
• Fit-system molds
• Visor molds
• Accessory molds
• Assembly fixtures

Our engineering team can also evaluate where components may potentially be shared across different helmet sizes to help manage tooling complexity and investment.