Injection Moulding Machine for Helmet Shells
Helmet shells in PC, ABS or PC/ABS are made on large horizontal injection moulding machines, usually one shell per mould. Projected area of the shell, its depth and the mould height decide machine size. Even wall thickness matters most, since impact performance in the approval test depends on it, so fill and packing must repeat every shot.
Machine selection for helmet shells centres on clamping force for the shell area, enough opening stroke to clear a deep core, and shot capacity with margin. Pratishna Engineers supplies horizontal and two-platen injection moulding machines for helmet shell production and can recommend a configuration for your shell and mould.
Moulding Helmet Shells?
Share your shell size, material and mould dimensions, and Pratishna Engineers will suggest a machine and send a quotation.
Machine Requirements for Helmet Shell Moulding
A helmet shell is a deep, curved part where wall consistency and mould size drive the machine choice. Points to check include:
- Clamping force for the full projected shell area
- Opening stroke and daylight for deep shell cores
- Shot capacity with margin for large PC shells
- Dryer sized for PC and PC/ABS before moulding
- Repeatable packing for even wall thickness across the crown
- Low moulded-in stress so painted shells resist solvent cracking
Recommended Machine for Helmet Shells
Helmet shells need high clamping force and a long opening stroke for the deep core. The H Series (120-350 T) suits smaller shells at the upper end of its range, while the Two-Platen PHM Series (160-350 T) gives the platen space and stroke that deep shell moulds need. Larger full-face shells beyond this range are discussed on request.
Not Sure Which Machine You Need?
Send your shell drawing and mould size for a machine suggestion.
Why Choose Pratishna Engineers?
- Application-Based Machine Selection
- In-House Engineering & Manufacturing
- Multiple Machine Series
- Production-Focused Solutions
- End-to-End Technical Support
- Industry-Specific Solutions
- Machine Lifecycle Support
Injection Moulding Machine Buyer Resources
Download practical resources to help you select, size and specify the right machine.
Horizontal Injection Moulding Machine Selection Guide
A step-by-step guide covering the key inputs needed to select the right machine: product weight, projected area, number of cavities, plastic material, required clamping force, shot / injection capacity, mould dimensions, production quantity, cycle time and automation requirement.
Download PDFPDF · 265 KB
How to Calculate Clamping Force for an Injection Moulding Machine
A clear methodology that explains how clamping force is calculated, covering projected area, injection pressure, safety factor, number of cavities and material considerations.
Download PDFPDF · 363 KBSports & Safety Components & Machine Guide
A guide to Sports & Safety components, covering helmet shells, visors, shin guards, mouthguards, padding, sports goods parts and fitness equipment parts. It explains impact grades, optical PC, two-material parts, and how to match each part to a suitable machine.
Download PDFPDF · 205 KB
FAQs / Buyer Questions
Questions helmet makers ask before choosing a shell moulding machine.
Which Injection Moulding Machine Is Used to Make Helmet Shells?
Shells sit at the top of the tonnage range. Smaller shells can run on an H Series machine near its upper limit, and deep full-face moulds suit the PHM two-platen design. Shells needing more force than these series offer are reviewed on request.Can Composite or Bicycle Helmet Shells Be Injection Moulded?
Fibreglass, aramid and carbon shells are laid up and compression moulded, a separate process. Bicycle helmet outer shells are thin formed sheet bonded to the foam liner. Injection moulding covers PC, ABS and PC/ABS shells.Is the EPS Impact Liner Made on the Same Machine?
No. EPS and EPP liners are steam moulded from expanded beads on a separate machine, often by another supplier. The injection moulding machine makes the shell, while visors, vents and trims come from smaller tools.
Why Does Drying Matter for PC Helmet Shells?
PC absorbs moisture, and wet granules cause splay and lower the impact strength of the shell. Dry the material before moulding, keep hopper time short, and check moisture when a new lot arrives.Can Pratishna Recommend a Machine for My Helmet Shell?
Yes. Share the shell drawing or a sample, material, shot weight, mould dimensions including height, and monthly volume, and Pratishna Engineers will suggest a machine and configuration.Does the Machine Suit Other Helmet and Protective Parts Too?
Yes, subject to the mould. Related parts include helmet visors and face shields, vent and pivot hardware, shin guards and knee or elbow guard shells, which usually need smaller machines than the shell.
Technical Disclaimer
Disclaimer: The information provided in this webpage is for general informational and educational purposes only. It is based on technical references and industry information available at the time of preparation and may be subject to change. It does not constitute engineering, technical, commercial or professional advice, nor does it constitute a quotation, specification, warranty or contractual commitment by Pratishna Engineers.
Actual injection moulding machine and process requirements vary according to the component design, material, mould, production volume, machine configuration and operating conditions. The information, examples, calculations and recommendations provided should be independently evaluated and verified for the specific application before making any equipment, process or production decision. Information obtained from third-party sources remains subject to the accuracy and limitations of those sources.
Limitation of Liability: Pratishna Engineers makes no representation or warranty, express or implied, regarding the completeness, accuracy or suitability of the information for any particular application. To the extent permitted by applicable law, Pratishna Engineers shall not be liable for any loss, damage, cost or consequence arising from reliance on or use of the information contained in this webpage. Final machine selection, configuration and application suitability should be confirmed with Pratishna Engineers based on complete and accurate project requirements.
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Planning a New Injection Moulding Project?
Share your component, material, mould and production target. Our engineering team will help you identify the right machine configuration.
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