EPS In-mold Technology

Helmet Technology
In-mold is the best current production technology for making ultra lightweight helmets with a high level of firmness and maximum protection. Injecting EPS (expandable polystyrene)foam directly into the PolyCarbonate shell in one operation created by pressure, heat and steam. PC shell is vacuum formed to the correct shape before in-mold process. It also prevents the shell from separating from the foam liner, and offers better transferring of impact force to the foam insert.

Working Principle
Comprised of closed-cell foam, EPS starts out as small beads comprised of styrene and an expanding agent.When the beads are heated with steam, the expanding agent begins to boil, the styrene softens and the beads expand. Allowed to stabilize for a period, the pre-expanded beads, which now have a closed cellular-foam structure, are packed in a mold made in the same shape as the finished helmet and again reheated with steam. The pre-foamed beads expand further, completely filling the mold and fusing together.

Applications
EPS is not only the main player in the cycling protection biz, but also can be used on other products by using the in-mold innovated technology, like: EPS lightweight drone, EPS lightweight fishing buoy, and EPS lightweight baby car seat.