One of the critical components in the development of our latest helmet was the selection and crafting of the padding that lines the inside of each helmet. After extensive research and testing, we chose closed cell foam for its superior benefits over open cell foam. Closed cell foam offered us the durability, water resistance, and overall comfort we were seeking, making it the clear choice for our design.

The Initial Challenges with Foam Padding

The initial stages of working with the closed cell foam involved cutting the padding by hand from larger sheets. This process was not without its frustrations. Achieving the precise sizes and shapes needed for the helmet's interior proved challenging, often resulting in inaccuracies that weren't aesthetically attractive. Additionally, the manual cutting process sometimes led to tearing, further complicating our efforts.

In the first prototypes, we used spray adhesive to affix the foam padding directly to the inner cover plates of the helmet. While this method initially seemed effective, it quickly became apparent that it was far from ideal. The adhesive was messy, making the assembly process more difficult than necessary. Furthermore, once the foam was in place, adjusting it for a better fit or replacing it was nearly impossible without causing a mess.

A Technological Solution: CNC Laser Cutting

Faced with these challenges, we decided to invest in a technological solution that would not only solve the issues at hand but also elevate the overall production process of our helmets. We purchased a CNC laser cutter, a decision that drastically transformed how we approached the creation of our helmet padding.

With the CNC laser cutter, we were able to precision-cut the closed cell foam using DXF files exported directly from SolidWorks. This method allowed us to achieve the exact dimensions and shapes required for the foam to fit perfectly inside the helmet, eliminating the inaccuracies and material waste associated with manual cutting. The precision of the laser cutter ensured that each piece of foam was consistent, fitting seamlessly into its designated spot within the helmet.

Enhancing Assembly with CNC-Cut Adhesive Velcro

The benefits of the CNC laser cutter extended beyond just cutting the foam. We also used it to cut adhesive-backed Velcro, which played a crucial role in attaching the foam padding to the helmet's inner plate sections. This approach provided several advantages. First, it made the assembly process cleaner and more efficient, eliminating the mess and permanence of spray adhesives. Second, it allowed for the foam to be easily adjusted or replaced by the user, ensuring that our helmets could be customized for comfort and fit over time.

The use of the CNC laser cutter for both the foam and Velcro has not only streamlined prototype iterations, but also makes higher volume production viable.