This article originally appeared on BikeRadar
BikeRadar recently visited Kask's production facility in Italy where we learned how a modern in-mould helmet is produced.
The exact model, whose production we shadowed, was Kask's long running and successful Protone road lid. It's this process, and slight variations of it, that sees Kask produce around 200,000 helmets a year in Italy.
You can think of a modern in-mould helmet as being made of two key parts: the shell and the liner. We kick off with the production of the shell below.
Thermoforming
KASK's Protone starts out life as a single polycarbonate sheet
In-moulding
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