Special process to connect outside shell and EPS as one, strong and light unit
In-mold is the best current production technology available for making ultra-lightweight helmets with a high level of strength and maximum protection. Injecting EPS (expandable polystyrene) foam directly into a polycarbonate (PC) shell in one operation created by pressure, heat and steam. The PC shell is vacuum-formed to the correct shape before the in-mold process. This also prevents the shell from separating from the foam liner and offers a better transfer of impact force to the foam insert.