In-Mold Construction is a technique that connects the shock absorbing
EPS liner directly to the polycarbonate shells to create a lightweight
and strong structure. In the first step, the flat PC sheet is heated and
deep-drawn over the helmet mold. Then the outline of the helmet shell
and the holes are milled out. This PC shell is then placed in the helmet
mold and the anchors for straps and fitting systems are placed.
Then the mold will be closed, and the EPS is injected.
Now the polycarbonate shell bonds with the EPS and a super light,
yet extremely stable helmet is created.