Helmet
Safety Helmet Shell Production
Client
Safety Equipment Manufacturer
Year
2023
Large-Scale Production of Impact-Resistant Helmet Shells
Our client needed to scale production of safety helmet shells that met stringent impact resistance standards while maintaining lightweight properties. The challenge was achieving consistent wall thickness and structural integrity across large production volumes.
The helmet shells required integrated ventilation systems and mounting points for accessories, adding complexity to the molding process. Quality standards demanded zero tolerance for structural defects that could compromise safety.
Production volumes of 100,000+ units annually required efficient processes and minimal waste to maintain competitive pricing.
High-Volume Injection Molding with Integrated Features
Stone Plastics implemented a large-tonnage injection molding solution using ABS/PC blend materials optimized for impact resistance. We designed multi-cavity tooling to maximize production efficiency while maintaining part quality.
Our process included integrated molding of ventilation channels and mounting features, eliminating secondary operations. Advanced process monitoring ensured consistent wall thickness and structural integrity.
The solution included: • Large-tonnage injection molding presses (300+ ton) • Multi-cavity tooling for high-volume production • Integrated ventilation and mounting feature molding • Real-time process monitoring and control • Automated quality inspection systems • Impact resistance testing protocols
Key Outcomes
100,000+ helmet shells produced annually
±0.005 inch wall thickness consistency
100% pass rate on impact resistance testing
Integrated features eliminate 3 secondary operations
30% reduction in production cost per unit
The quality and consistency of helmet shells from Stone Plastics has been exceptional. Their ability to integrate complex features during molding has streamlined our entire production process.
Sarah Chen
Production Director, SafeGuard Equipment
Project Gallery
Completed safety helmet shells
Multi-cavity injection mold
High-volume production line
Impact resistance testing facility
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