A practical guide for businesses planning to launch or expand their own helmet brand. Launching a helmet brand is an exciting opportunity, but not every business needs to begin with custom manufacturing. At Aurora Sports, we receive inquiries from entrepreneurs, emerging brands, distributors and established companies looking for helmet products. Some customers need only 30 […]

For helmet brands and design studios, the biggest tooling challenge is usually not making the mold itself. The real challenge is keeping the original design intent intact while moving from concept to engineering, tooling, testing, and finally mass production. When those steps are handled by different suppliers, common problems can appear quickly: The design looks […]

Good helmet padding is more than a flat piece of foam covered with fabric. The inside of a helmet is a curved, three-dimensional space, so the padding needs to be engineered around the helmet’s geometry, ventilation, fit system, attachment points, and intended use. At Aurora Sports, we develop custom helmet padding from 3D design through […]

Bump caps are designed to provide lightweight head protection for workers who may accidentally strike their heads against low ceilings, shelving, pipes, machinery or other stationary objects. Although the concept is simple, the wearing experience often is not. Common complaints include poor fit, pressure around the forehead and temples, excessive heat, movement during use, odor, […]

What Makes a Better Helmet Liner? Materials, Comfort and Customization The inside of a helmet deserves just as much attention as the outside. A well-designed helmet interior combines fit, comfort, breathability, durability and application-specific performance. At Aurora Sports, we develop custom helmet liner and padding solutions for different sports, work environments and product requirements. Our […]