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Beyond Helmets: Advanced EPS Molding for Lightweight Products & Seamless Component Integration

When most people think about EPS — Expanded Polystyrene, they may think of helmet liners or protective packaging. But EPS molding technology can be used far beyond helmets. Because EPS combines extremely low weight, energy absorption, thermal insulation, buoyancy and the ability to form complex three-dimensional shapes, it can be engineered for products across transportation, […]

Cold-Press vs. Hot-Press Helmet Liners: How to Choose the Right Manufacturing Process

When developing a helmet, the liner may look like a relatively small component, but its materials, construction, comfort, moisture management, durability, and manufacturing process can significantly affect the overall user experience. At Aurora Sports, we work with customers on custom helmet development and manufacturing, including liner structures using different combinations of foam, EVA, TPU, D3O-type […]

Developing a Helmet Comfort Liner? Start With the Right Forming Process — Not Just the Material

You are developing a new helmet—or improving an existing model. Traditionally, helmet comfort liner development often starts with one question: “What material should we use?” But in real-world helmet development, material selection cannot be separated from the manufacturing process. The forming method can influence which helmet padding materials are practical, how precisely the liner can […]