How and where we produce

 
Where we produce

CAST helmets are entirely produced in Italy by companies belonging to the BELL Safety group, leader in the production of military and professional helmets by specializedpersonnel with long experience.

 Shells

The materials we use

For the shells, neglecting the characteristics of helmets in Plastics Resin, generally suitable for Jet or cheap helmets, we evaluate the differences between the Fibers used to obtain the best performing helmets.

The helmets commonly called "in Fiber" are produced by impregnating with a "binder" hardener resin a fiber that acts as a supporting structure and determines the strength and characteristics of the helmet.

The normal glass fiber is the most economical and less resistant supporting component as well as heavier, the weight / strength ratio is very disadvantageous.

 
A cheap fiber helmet check it out with a "high" weight

The Multiaxial fibers possibly reinforced with Carbon or Aramidic greatly increase this ratio for which light and resistant helmets are obtained.

The maximum of this weight / strength ratio is obtained by using carbon fibers impregnated with epoxy resins and is currently the best high-tech material that the industry is able to produce in appreciable quantities.

A carbon fiber is a long and thin wire largely composed of carbon atoms, several thousand carbon fibers are intertwined together to form a fabric with a very high tensile strength. To give an idea, the tensile modulus or the resistance that can withstand without breaking is more than 140 M.psi for more resistant and quality fibers.

To make a comparison, steel has a modulus strength of about 29 M.psi, so the best carbon fiber is about five times stronger than steel (and lighter).

The carbon fiber fabric obtained from thin carbon filaments arranged according to the classic warp and weft scheme, is impregnated with epoxy resins to obtain helmets with exceptional strength and limited weight.

The production takes place by hot molding after exact stratification of the fabrics and impregnation of the resin or by autoclaving.

Historically, the best production of carbon fiber products is recognized as "Made in Italy" or "Made in England" areas of great development in this sector (F1 auto experience) and where it resides personnel with long experience

This is due to the type of carbon fiber used and the operator's experience

How we produce

The first phase is the cutting of the various sectors in carbon fabric, carefully checking the sense of the fibers.

The operator then inserts the various sectors into the heated mold according to a pattern pre-established by tests which have determined the best resistance yield.
This operation must be carried out with high precision and attention as it determines the quality of the helmet that will be obtained.
 

The operator injects with an automatic system in the mold heated to an exact temperature a precise dose of pre-mixed liquid epoxy resin, inserts the counter-mold which adheres precisely the resin measured on the whole surface of the mold or of the cap.
The controlled temperature and the catalyst make the resin harden evenly.
The only molding cycle to obtain a quality product is about 40 minutes or more for a rough shell, then the cap must undergo all other processes.
     
The molding cycle while being mechanized is subject to the experience of the operator or the quality of the helmet obtained often depends on the skill and experience of the person who produces it and controls it.

We proceed to the milling of the window and the holes of the rough shell with a diamond-coated CNC cutter or with a water cut, which precisely ends up.

The last phase of production of the shell is that of grinding to eliminate the burrs, and then painting with special paints that have a low coefficient of thermal expansion in order to not have cracking over time due to the high stability of the shell.
     
Visors

All Cast helmets visors are produced in our factory equipped with automatic molding presses, and robotic systems for the treatment of surface hardening and anti-fog.
     
How we produce visors
The Lexan visor is printed with presses equipped with robots that, in addition to manipulating them, will engrave the Laser brand and the production lot identification code.

Then they are inserted into the surface treatment plant in an area with a controlled atmosphere free from impurities. After suitable pre-washing and drying a robotized system impregnates the external part of Xiloxane which, after polymerization at a regulated temperature, gives the external part of the visor a high degree of resistance to scratch, (about 300% higher than what is prescribed by the ECE regulation 22.05).

Therefore always automatically the visor continues its "way" and a second robotized system impregnates the inner part (and only this one) of a special component that gives an excellent anti-misting power, the whole ends with a second temperature-regulated polymerization.
The anti-fog treatment is the best on the market today without resorting to internal visors that diminish the optical quality, it is permanent, and washing periodically with soap and water restores itself in the initial conditions.

The molding department produces all the components necessary to complete the helmet
Interior

the fabrics we use

We care about your health, as well as your safety.

For this we use fabrics produced in Italy and certified free of substances harmful to your health.

In fact, it is now established that the fabrics inside the helmet, in the presence of harmful substances can give allergies, eczema and transmit highly toxic and carcinogenic materials in the body.

This is why all the fabrics of our helmets, manufactured in Italy, are tested and CERTIFIED
STANDARD 100 by OEKO-TEX ® free from these substances.

                                             

The helmet will then be assembled with the various components.
Last but not least, the fundamental routine tests that check the compliance with the required homologation requirements.

See the Video of our production:

https://youtu.be/jBkjiRMsa5s