How are bike helmets made?

Bike helmets are made through a manufacturing process that involves multiple steps and materials. The most common type of bike helmet is made using a hard outer shell made of polycarbonate or ABS plastic. This outer shell helps to absorb and distribute impact energy in the event of a crash. Inside the helmet, there is usually a layer of expanded polystyrene (EPS) foam. This foam is designed to absorb the energy from an impact and protect the rider's head. The EPS foam is often molded into the desired shape using heat and pressure. Additionally, many modern bike helmets also include additional features such as adjustable straps, ventilation channels, and removable padding for added comfort. These components are typically added during the manufacturing process, along with the necessary hardware and fasteners. Overall, the manufacturing process for bike helmets involves a combination of molding, assembly, and finishing to create a high-quality and protective product for cyclists.