Helmet plastic mold

Core Product: Custom Helmet Plastic Molds

We specialize in the customized design and manufacturing of high-precision helmet plastic molds, which are core production equipment for key components of various helmets (motorcycle helmets, bicycle helmets, sports helmets, industrial protective helmets). Our core function is to provide durable, high-precision injection molds that realize integral forming of helmet structures (outer shells, inner liners, chin guards), ensuring consistent dimensional accuracy, excellent impact resistance, and tight structural bonding—critical for helmets to meet international safety certifications (CE, CPSC, ASTM). Backed by a professional technical team of 35+ engineers and technicians, we leverage advanced CAD/CAM/CAE software (UG, AutoCAD, SolidWorks) to conduct in-depth simulation of the injection molding process for helmet components, optimizing mold cavity structure, gate design, and cooling system layout to avoid defects such as wall thickness unevenness, shrinkage, and structural weak points. Our molds are tailored to match the material characteristics of helmet parts (e.g., high-impact ABS, PC, EPS) and mass production needs, featuring large cavity precision control, short molding cycles, and long service lives.

Production Process & Supporting Technologies

The production of our helmet plastic molds follows a strict standardized workflow that focuses on safety and structural stability: 1. Demand Analysis & Design (confirm client’s helmet type, safety standard requirements, material selection, and production capacity; conduct 3D mold modeling and injection process simulation to verify structural strength and impact resistance); 2. Raw Material Preparation (select high-quality mold steel (S136, H13, P20) with excellent wear resistance and thermal stability, suitable for large cavity helmet mold manufacturing; implement precision cutting via CNC flame cutting equipment); 3. Precision Machining (carry out CNC milling, grinding, EDM, wire cutting, and high-speed machining to ensure the machining accuracy of mold cores, cavities, and structural components, with key dimensions controlled within ±0.005mm; focus on large cavity surface finish and wall thickness uniformity); 4. Assembly & Debugging (skilled technicians perform manual assembly, install hot runner systems (for large helmet shells), and conduct multiple rounds of debugging and trial injection to optimize molding parameters and ensure structural consistency of helmet parts); 5. Quality Inspection & Delivery (use coordinate measuring machines (CMM) and impact testing equipment to inspect mold dimensions and structural performance of trial products; conduct safety performance sampling tests to ensure compliance with international standards, and provide test reports). In addition to specialized helmet plastic molds, we also provide supporting processes such as surface treatment (painting, UV coating, matte processing), finished helmet assembly, and packaging, achieving full-chain service for clients.

Common Problems & Solutions in Helmet Plastic Mold Production

• Problem 1: Uneven wall thickness of helmet shells (affecting impact resistance) - Solution: Optimize the mold cavity design and gate layout via CAE simulation to ensure uniform plastic flow; adjust injection speed and pressure gradient to control material filling rate; use high-precision machining equipment to ensure the consistency of mold cavity wall thickness; install pressure sensors in the mold to monitor filling pressure in real time.

• Problem 2: Shrinkage marks and sink marks on the helmet surface - Solution: Improve the mold cooling system layout, add cooling channels in thick-walled areas of the helmet to ensure uniform cooling; increase injection pressure and holding pressure appropriately to compensate for material shrinkage; optimize the plastic material formula (add nucleating agents) to reduce shrinkage rate; polish the mold cavity surface to enhance finish and reduce shrinkage mark visibility.

• Problem 3: Poor structural bonding of helmet composite parts (e.g., shell + inner liner) - Solution: Optimize the mold’s positioning and clamping mechanism to ensure precise alignment of composite parts; adjust injection parameters (temperature, pressure) to enhance material fusion between different components; design a special bonding groove structure in the mold to increase the contact area between parts; conduct compatibility testing of composite materials in advance.

Frequently Asked Questions (FAQ)

• Q1: What types of helmet plastic molds can you produce? - A1: Our molds can produce various helmet-related plastic components, including motorcycle full-face helmet shells, bicycle helmet outer shells, sports helmet inner liners, and industrial protective helmet chin guards. We support customization based on client-specific helmet designs and international safety standard requirements (CE, CPSC, ASTM).

• Q2: What is the lead time for custom helmet plastic molds? - A2: The lead time varies by mold complexity (helmet size and structure): sample molds take 10-20 working days, mass production molds take 25-50 working days, and urgent orders can be completed in 7-15 working days with an additional fee. The longer lead time for large helmet molds is due to the complex large cavity processing and strict safety performance debugging requirements. We will provide a detailed production schedule after confirming the order.

• Q3: Do you provide quality assurance for your helmet plastic molds? - A3: Yes, we provide a 12-month quality guarantee for all injection molds. During the guarantee period, if there are quality problems caused by mold design or manufacturing (e.g., wall thickness unevenness, structural deformation), we will provide free repair or replacement services. We also offer lifelong technical support for mold maintenance and parameter optimization to ensure stable mass production of safe helmets.

• Q4: Can you provide injection molding services for finished helmet components? - A4: Yes, we are equipped with 20+ high-precision large-tonnage injection molding machines (200-1000 tons) that can meet the production needs of large helmet shells and complex components. We can provide one-stop services from mold design, fabrication to finished helmet part injection molding and assembly, which can effectively reduce your communication costs and shorten the production cycle.

• Q5: Do your helmet molds and finished components meet international safety certifications? - A5: Our factory is certified by ISO9001:2015 and IATF16949. The plastic materials we use for helmets comply with RoHS and REACH certifications, and the finished helmet components produced by our molds can pass international safety tests (impact test, penetration test) required by CE, CPSC, and ASTM. We can provide relevant certification documents and test reports according to client requirements.

Product Classification & Technical Specifications

1. Product Classification by Industry, Material & Part Type

2. Technical Specification Parameters

Our Core Competitiveness

• 10+ Years of Helmet Industry Expertise: Founded in 2012, we have focused on helmet plastic mold manufacturing, serving more than 200 clients from over 40 countries, including leading helmet manufacturers in Europe, North America, and Southeast Asia. Our rich experience enables us to accurately grasp the strict safety standards and technical requirements of the global helmet industry.

• Professional Technical Team: A team of 100+ engineers and technicians with an average of 8+ years of industry experience, proficient in the design and optimization of helmet plastic molds. They are skilled in handling technical difficulties such as large cavity precision control, impact resistance structure design, and safety standard compliance.

• Strong Production Capacity: Our factory covers an area of 12,000 square meters, equipped with 100+ sets of advanced production and testing equipment (CNC milling machines, EDM machines, wire cutting machines, CMM, large-tonnage injection molding machines, impact testing machines, etc.), with an annual production capacity of 200+ sets of injection molds and 15 million+ finished helmet components.

• Strict Quality Management System: Certified by ISO9001:2015 and IATF16949, we implement full-process quality control from raw material incoming inspection to finished product delivery. We have established a professional quality inspection team and equipped with complete safety testing equipment to conduct strict inspections on mold precision, material performance, and product impact resistance, ensuring compliance with international safety standards.

• Improved Supply Chain: Cooperate with reliable domestic raw material suppliers to ensure stable supply and consistent quality of safety-certified plastic materials and mold steel; integrate upstream and downstream resources to realize cost optimization and timely delivery, effectively supporting clients' mass production plans.

• Global Service Capabilities: Cooperate with well-known international logistics companies (Maersk, COSCO) to provide efficient and safe global shipping services, leveraging the geographical advantage of Qingdao Port to shorten delivery time. We offer 24-hour online technical support and a 12-month quality guarantee to solve after-sales problems promptly for clients around the world.

Customer Case: Helmet Plastic Mold Project for European Motorcycle Helmet Client

Our client is a leading motorcycle helmet manufacturer in Europe, specializing in the production of high-end safety-certified motorcycle helmets. They encountered problems with their original plastic molds for full-face helmet shells, including uneven wall thickness (tolerance exceeding ±0.3mm) which led to failure in ECE R22.05 impact tests, which affected their market supply. In 2023, they partnered with us to customize a set of high-precision plastic molds for their new model of ECE R22.05-certified full-face helmet shells.

Our technical team first conducted a detailed analysis of the client’s helmet shell drawings and ECE R22.05 safety standard requirements. We used UG software to build a 3D model of the helmet plastic mold and simulated the injection molding process, optimizing the mold’s gate layout (adopting 4-point balanced gating) and cooling system (adding 32 cooling channels in key thick-walled areas) to ensure uniform wall thickness and cooling. We selected high-impact H13 mold steel and implemented a strict heat treatment process to enhance the mold’s wear resistance and service life. During the debugging stage, we adjusted the injection parameters (speed, pressure, holding time) for multiple times and conducted impact tests on trial-produced helmet shells to verify compliance with ECE R22.05 standards.

The final delivered injection molds achieved excellent results: the wall thickness tolerance of the helmet shells was controlled within ±0.1mm, and all trial products passed the ECE R22.05 impact test; the mold service life was guaranteed to be more than 1.2 million shots. The client highly recognized our product quality and technical service, and signed a long-term cooperation agreement with us, covering multiple models of motorcycle helmet molds.

Why Choose Qingdao Xinlongji?

1. Professional Customization for Helmet Industry: We focus on the R&D and manufacturing of helmet plastic molds, with in-depth understanding of international safety standards (CE, CPSC, ASTM) and helmet structural design requirements, ensuring that our solutions help you produce safety-certified high-quality helmets.

2. One-Stop Integrated Service: From mold design, fabrication to finished helmet part injection molding and assembly, we provide a full range of services, helping you simplify the supply chain and reduce communication and management costs.

3. Proven Technical Strength: Our professional technical team and advanced simulation technology can effectively solve various complex problems in helmet plastic mold production (e.g., uneven wall thickness, impact resistance), ensuring product quality and production efficiency.

4. Reliable Quality Assurance: International quality system certification and full-process safety performance testing ensure that our products comply with global helmet safety standards, minimizing your production risks and helping you enter the international market smoothly.

5. Efficient Global Support: We have rich experience in international helmet trade and perfect global logistics channels, ensuring timely delivery of products to your designated location. Our 24-hour technical support team provides professional after-sales services to solve your worries during the production process.

Qingdao Xinlongji Metal Manufacturing Co., Ltd. is committed to becoming a trusted partner in the global helmet plastic mold industry. We look forward to cooperating with you to create safer and higher-quality helmet products for the global market! For more information about our products and services, please feel free to contact us.