Football Helmet Pads&Shims
Customer Requirements
Client Profile: One of America’s top manufacturers of football helmets
Application: Installed inside football helmets for shock absorption and protection
Core Demand: Cut costs substantially as a replacement for local sourcing
Preliminary Solution
We adopt Custom Vacuum Fusing Mold. The five-layer composite material (PU, Memory Foam, EVA, TPU and hook-and-loop fabric) is integrally formed within the mold in one process.
Final Verified Solution
Poor forming results occurred on the outer PU layer during pilot trials. We revised the production workflow: pre-form the PU sheet in advance, then laminate and trim it alongside the remaining layers inside the mold. Final finished goods deliver stable quality and premium surface appearance.
Vacuum Fusing Mold:
Inside:
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