Helmetmaking

Helmetmaking is the process of manufacturing protective headgear. This involves designing, shaping, and assembling materials to create a durable and impact-resistant shell, along with an internal suspension or padding system for comfort and shock absorption. Historically, helmetmaking relied on metalworking, crafting helmets from iron, steel, or bronze for military purposes. Modern helmetmaking utilizes a wider range of materials including thermoplastics like polycarbonate and ABS, composite materials such as fiberglass and carbon fiber, and advanced foams like expanded polystyrene (EPS).

The manufacturing process typically begins with the creation of a mold based on the helmet's design. For plastic helmets, this often involves injection molding or blow molding. Composite helmets are usually made using layup techniques where layers of material are impregnated with resin and cured. The internal components, such as the liner and retention system (straps and buckles), are manufactured separately and then integrated with the shell. Safety standards and rigorous testing are crucial in helmetmaking to ensure effectiveness in protecting against various types of impacts, from blunt force to penetration. Helmets are produced for a diverse range of applications, including sports, construction, motorcycling, and military use, each with specific design considerations and material requirements.