WHAT WE CAN ACCOMPLISH
If you want to learn more about us, you’re in the right place. Read to learn on how we could build your helmet brand line-up
DESIGN
Concept sketch, CAD and mock-up fabrication. working with clay modeling or full FDM 3D printed models to have early visualization and direction to development product.
TOOLING
Full line of tools are able to be built. ABS/PC, micro shell forming, EPS over molding, plastic parts and components, ultrasonic pressed padding. All the necessary bundle to build perfect helmet.
PROCESS
From injection molding to EPS + Micro-shell over-molding all the needed process to build the helmet components can be done with Sports Plus.
CERTIFY
Sports Plus will build your product in full and take responsibility in getting it tested and certified for your region without complications.
PRINTS
All printable from manuals, packing option and decoration to the helmet will be handled for the conveniences of our clients.Give us the design guide or we can propose the design for you.
LET SPORTS PLUS FINISH THE JOB
Sports Plus will take on the project forward and finish the job with absolution.
DESIGN and MOCK-UP FABRICATION
CONCEPT DESIGN
Concept and outlook sketch can be proposed from our location for your interests, let us advance from here to get started on what might work for you.
CLAY MODELING
From concept design to actual visualization of the product can be experienced from model which crafted by the artist clay modeler.
CAD MODELING
Full surface modeling can be built in-order to adapt into product. Advantages will be of having early full color and design visualization can be appropriated.
FDM FABRICATION
Once surface 3D CAD model is put together we are able to print it for actual visualization and testing of the possible product. Sense in ventilation, comfort, size,visual feel can be analysed.
TOOLING
INJECTION MOLD (PARTS)
Customized fit system, helmet skeletal parts, strap buckle or divider will required for its own tools. To have brands own unique identity we will build all the tools needed for plastic components.
HARD ABS SHELL MOLD
BMX helmet usually work with hard outer shell helmet. Hard outer shell require ABS or PC Shell tooling.
EPS + MICRO SHELL IN MOLD
Pre-formed micro shells are bonded together with EPS In-mold tool.
EPS MOLD
Conventional hard shell helmet is likely to work with separate inner EPS component which can be inserted into the shell, in such cases separate EPS tool is made.
MICRO SHELL FORMING
0.5 mm ~1.0 mm thick outer bicycle micro shell reinforcement is made by micro shell forming tool.
HEAT PRESS TOOL
Inner padding of the helmets are made by heat pressing tool in various shapes and sizes.
FULL PRODUCTION
INJECTION MOLDING
Injection molding process for all the plastic parts and components, for diverse helmet applications.
HARD ABS SHELL MOLDING
Whole outer hard plastic shell is injection molded with ABS or PC composite material.
EPS + SHELL IN-MOLDING
Preformed micro shell is inserted into EPS in- mold tool to final bond and form EPS on to the micro shell with pressurized heated steam.
COATING
Matt outlook or partial glossy outlook of helmet is done through coating process.
HEAT | ULTRASONIC PRESS
Inner padding of the helmets are pressed and and cut via Heat press process. If netting or fine edges are needed we can also go with ultrasonic processing.
ASSEMBLY
All assembly and are fully managed with 100% quality inspection standards.
EPS MOLDING
Prepared EPS grains is bonded together by extreme pressurized steam to form the inner shape of the helmet.
MICRO SHELL FORMING
In-order to shape the outer protective layer into bicycle helmet, micro shell forming stage is applied.
ROBOT MICRO SHELL CUT
Excess shells are precision cut with robot XYZ cutter.
SILK SCREEN PRINTING
Various colors and designs on the helmet is pre-printed on to the raw micro shell sheet material.
SEWING
Helmet straps are gone through sewing process in preparation of WIP helmet components for helmet assembly.
TESTING AND CERTIFICATION
CE EN 1078
European regional bicycle helmet certification. European Safety Standards for pedal cyclists, skateboarders and roller skaters CE EN 1078 certification is needed. Sports Plus will certify the product for our clients.
CPSC
US region, U.S. Safety Standards for bicycle helmets CPSC certification is needed.
ONSITE IMPACT TEST SIMULATION
PRINTS and PACKAGING
TPR DECO
TPR Thermal Plastic Rubber is beveled decorated components sometimes used on helmet straps its self or helmet binder as decorative outlook.
COLOR CARTON
Custom design color carton for unique packaging is possible. idea in packaging design is a start.
DOME | ALUMINUM STICKERS
For distinction and identity, dome stickers or aluminum stickers are used for decorative helmet logo or decorative Re-tension Fit System. Also standard vinyl stickers are done for various labeling.
MANUAL
If not going with standard manual clients can prefer to obtain customized manual. Also special hang-tags can be printed for further enhance the value of the product.