Multiple Helmet Manufacturing Technologies
Modern helmet manufacturing rarely relies on only one production process.
Depending on the helmet category, design objectives and certification requirements, Aurora can integrate multiple technologies into a single product.
EPS In-Mold Technology
In-mold construction integrates a thin polycarbonate shell with an EPS impact-absorbing liner.
It is commonly used for lightweight and highly ventilated helmets such as:
- Road cycling helmets
- Mountain bike helmets
- Gravel helmets
- Urban helmets
- E-bike helmets
Injection-Molded Components & Shells
Plastic injection molding can be used for helmet shells, fit-system components, visors, adjustment systems, structural elements and other functional plastic parts.
Material and tooling design are selected according to the requirements of the individual product.
ABS Shell Construction
ABS shells are commonly used in helmet categories where a durable rigid outer shell is required.
Depending on the project, ABS shell construction may be combined with EPS liners, fit systems and other components to create the complete helmet structure.
Carbon Fiber & Composite Technology
For premium or performance-oriented products, carbon fiber and other composite materials can be considered for:
- Full composite shells
- Hybrid constructions
- Structural reinforcement
- Lightweight performance designs
Polycarbonate Vacuum Forming
Vacuum forming can be used to produce thin, lightweight polycarbonate shells and other thermoformed components.
For many bicycle helmets, a vacuum-formed PC shell is subsequently integrated with the EPS liner during the in-mold process.
