Ningbo Toprise Security Products Co., Ltd., as one of China’s leading safety helmet manufacturers since 2009, is committed to providing effective safety helmets for customers around the world. We produce safety helmets in strict accordance with the international market CE and ANSI standards for production. The following is to share with you our safety helmet production process.
Step 1: Raw material processing
The first step is the selection and treatment of raw materials: the safety helmet materials we produce are mainly HDPE and ABS materials. We will recommend suitable materials according to the area where the customer uses the helmet. Generally, HDPE materials are lightweight and durable and suitable for industrial environments, while ABS plastics are widely used in high-risk operations due to their strength and impact resistance. We pretreat the material to ensure stable physical properties in subsequent production.
Step 2: Injection of the safety helmet shell
The plastic particles first need to be put into the hopper of the injection molding machine; through heating and melting, the plastic can be molded into a molten body. Then, the molten plastic is injected into the mold through the injection cylinder of the injection molding machine, and the cavity in the mold will be filled with plastic to form the shape of the plastic safety hat.
Step 3: Trim the edge to remove the burr.
Take out the formed safety helmet shell, trim the excess edge and burr, and make its edge smooth.
Step 4: The production of the helmet lining and chin strap.
The lining of the safety helmet can indeed be made of plastic sheets and webbing by sewing or hot pressing. The design of the lining is often based on robustness and durability, while providing a certain shock absorption effect to ensure effective protection for the wearer during the working process. The following is the production process of the safety helmet lining:
1. Material selection
Plastic sheet: Usually use high-strength, lightweight plastic sheet as the skeleton part of the lining. These plastic sheets are specially treated and have good toughness, which can effectively disperse the external impact force and avoid direct effect on the wearer’s head.Webbing: The webbing part usually uses high-strength materials such as nylon or polyester. These webbings not only have strong wear resistance and tensile strength but also provide better air permeability and comfort when worn.
2. Plastic sheet molding
Mold molding: The plastic sheet is molded by injection molding or die process, and the plastic frame is made according to the design size and shape, which is in line with the internal structure of the safety hat. These plastic sheets are usually processed several times to ensure that they have sufficient toughness and durability.
Punching and adjustment: In order to be able to combine the webbing with the plastic sheet, the plastic sheet will punch a number of precise fixed holes. These holes are used to hold the webbing in place, making the entire lining system more stable.
3. Production of webbing
Ribbon cutting: According to the design requirements of the helmet lining, the ribbon will be cut to the appropriate length and width. The length design of the webbing needs to take into account the needs of head circumference adjustment to ensure that the wearer can adjust according to their own head size.
Webbing reinforcement: In order to ensure the fastness of the webbing during use, the webbing is usually reinforced at a specific location. This may include thickening the webbing, using reinforcing wires, etc.
4. Sewing or hot pressing combination of plastic sheet and webbing
Sewing process: plastic sheet and webbing are combined by the sewing process. The two ends of the webbing pass through the fixing holes in the plastic sheet, and it is firmly fixed to the plastic sheet using high-strength sewing thread. The sewing process requires great precision to ensure that each connection is strong enough not to come loose after a long period of use.
With the progress of science and technology, plastic sheets and webbing are now fixed by hot pressing, which is more efficient and more beautiful.
Step 5: Logo of the Helmet
We can support customers to customize the helmet with their own logo. Our helmet design has a movable metal module. We can help customers directly customize the metal module with the customer’s logo; this position is often inside the brim. In this way, after the hat shell is formed, the customer’s logo is directly on the helmet shell. It is also possible to help guests print the logo directly in front of the helmet shell, usually screen printing, which is often more efficient and economical. In addition, we can also, according to the requirements of customers, help customers customize the self-adhesive with the customer’s logo, often affixed to the inside of the cap shell at the back of the head.
Step 6: The safety helmet assembly
This step can be selected by the customer. Most of the time, in order to help customers save transportation costs, we will ship the helmet in bulk; the hat shell is stacked in boxes placed on the top, and the bottom is covered with the helmet liner and chin strap. If the customer has special requirements, we will also help the customer directly install the lining and chin strap directly into the helmet housing. The user can adjust the helmet to a comfortable position by adjusting the buckle behind the helmet or rotating the button during use.
Step 7: Safety helmet quality testing.
Our safety helmet production will be in strict accordance with the European standard CE or American standard ANSI and other standards for production. Each batch of helmets produced by our company will undergo strict quality testing, covering impact resistance, puncture resistance, electrical insulation ability, weather resistance, etc., to ensure effective protection of products in various working environments.
Step 8: Package and ship
We can help customers customize plastic bags with customer logos, a helmet into a plastic bag. The containers are stacked into each other. We will customize the corrugated box with five layers of reinforcement to avoid damage to the outer box during the luck.
The above is the detailed production process of our Ningbo Toprise Security Products Co., Ltd. If you have any questions about the production of hard hats or have any demand for hard hats, feel free to contact us for communication and a quotation.
