Tooling mold
Tooling & Mold Capabilities
Before we begin tooling any mold, we take the time to understand what kind of helmet you’re developing. Is it designed for industrial safety, equestrian riding, snowboarding, or high-performance sports? Each helmet type comes with its own structural and performance demands—and that directly affects the tooling strategy.
At our factory, we don’t outsource the critical steps. Our in-house tooling workshop gives us full control over the design, fabrication, and maintenance of molds for polycarbonate (PC), acrylonitrile butadiene styrene (ABS), and expanded polystyrene (EPS)—the three fundamental materials in helmet construction. Here’s how each fits into the equation.
Polycarbonate (PC) Tooling – In-Mold Shells
for lightweight performance
Polycarbonate is widely used for high-performance helmets—particularly in cycling, snow sports, and climbing—thanks to its toughness, transparency, and lightweight properties. PC shells are typically formed through in-mold technology, where the PC is directly fused to the EPS liner during molding. This creates a seamless, durable structure that’s both sleek and aerodynamic.
To support this, we use aluminum tooling molds for polycarbonate. These molds are cost-effective, especially for mid-range production runs, and allow us to maintain smooth finishes and complex geometries. PC molds are excellent when agility and design flexibility are key, and you want a modern, one-piece shell.
Applications:
- Bicycle and snow helmets
- Mountaineering helmets
- Helmets with aerodynamic or curved designs
ABS Plastic Injection Tooling – Rugged Shells for Industrial & Utility Use
Durability and impact resistance
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Tougher, heavier, and better suited
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The complexity of shell vents
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ABS isn’t limited to just helmet shells
It’s also widely used across a range of plastic accessories and components. In our workshop, ABS injection tooling can be adapted to produce:
- Headlock adjusters
- Helmet visors and clips
- Ventilation covers and chinstrap systems
- Tool housings
- Protective casings for electronics
- Automotive trim and dashboards
- Luggage shells, keyboard keys, and phone casings
Because ABS balances durability and processability, it’s one of the most versatile materials we use for both functional and aesthetic parts. Helmet-related applications:
- Industrial safety helmets (ANSI Z89.1)
- Equestrian riding helmets
- Modular plastic components integrated into helmets
- Skateboarding Out-mold
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Our product guaranteed quality, compliance with regulations
There are more than 300 brand factories with employees and more than 50,000 square meters of factory buildings. All products are tested in accordance with product standards and testing protocols before all product development, processing, and shipment.
