It’s widely known that wearing a helmet is an essential factor in improving a cyclist’s safety and that they are designed to protect against head injuries in the event of a crash, but have you ever wondered how they’re made? 

Here, we’ll take an in-depth look at the manufacturing process behind our cycling helmets, from the initial molding phase right the way through to the finished product. 

Our helmets start out as a single sheet of transparent polycarbonate.

Every sheet is inserted into a silkscreen printing machine where colors are applied using printing ink and a frame.

Every model in the KASK range uses a bespoke frame through which the color is applied and then left to dry. 

Once dried, the colored sheet is placed in a thermoforming machine.

Heated by infra-red lamps, the sheet is shaped around a steel mold, using vacuum.

This process produces the upper and lower outer shells of the helmet.

Both shells are then cut out and finished using a cutting robot.

Next, the two parts of the outer shell are co-molded to the inner EPS (which stands for ‘Expanded Polystyrene Shell’).

This stage is also where inserts such as the size adjuster and chin strap anchorages are incorporated.

The final stage sees the safety systems, labels, and all internal padding being attached to the helmet. In helmets such as the Elemento, KASK’s Multipod technology is incorporated into the assembly during this phase. 

Multipod, designed exclusively by KASK, is 3D printed with elastomeric material and allows for better management of impact energy whilst also improving helmet ventilation.

All our helmets are manufactured in Italy to guarantee they meet the demands of cyclists who expect the very highest quality, and the very best protection.

Every one of our helmets is rigorously tested and passes our KASK Rotational Impact WG11 Test. 

Wondering which helmet is right for you? Visit our guide to buying the perfect road helmet here.