The Most Reliable Helmet Supply Chain Partner.

For a serious helmet brand, a manufacturing partner with an in-house testing facility is not a luxury—it's a necessity. An in-house lab, like the one at the core of SPIRIT's operations, provides three immense advantages. First is speed in development. When our R&D team develops a new prototype bike helmet, we can test it for impact absorption and structural integrity within hours, not weeks. This allows for rapid iteration and innovation. Second is quality assurance. We conduct continuous batch testing on helmets pulled directly from the production line, ensuring that every unit maintains the same high safety standard as the original certified model. This goes far beyond the minimum requirement of a one-time certification test. Third, and most importantly, is risk mitigation. By pre-testing every new bike helmet design to CPSC and CE standards, we can identify and solve any potential issues before submitting the helmet for official, expensive third-party certification. This dramatically reduces the risk of a costly failure and ensures a smoother, faster path to market for our partners.

Navigating safety standards is a critical hurdle for any global helmet brand. The two most prominent standards are CPSC for the United States and CE EN 1078 for Europe. While both ensure a baseline of safety, they differ in their testing protocols. The CPSC standard, for example, generally involves impact tests from greater heights, demanding a higher level of impact absorption. The CE standard has specific requirements regarding the field of vision and coverage area. For a brand selling in both markets, creating a single bike helmet that meets both sets of criteria requires expert engineering and rigorous testing. At SPIRIT, this is a core competency. We design our helmets from the ground up with global compliance in mind. Our in-house testing center is equipped to test for both CPSC and CE protocols, ensuring that every bike helmet we ship is ready for its target market without costly redesigns or delays. Partnering with SPIRIT removes the complexity of compliance, allowing you to focus on building your brand with the assurance of universal safety.

The creation of a high-performance bicycle helmet is a marvel of modern manufacturing, centered around a technique called in-mold construction. This process is key to achieving the light weight and strength that top-tier helmets are known for. It begins with a thin, durable polycarbonate outer shell, which is placed into a precision-engineered mold. Then, tiny expanded polystyrene (EPS) foam beads are injected into the mold under intense pressure and heat. The heat causes the beads to expand and fuse together, forming the protective inner liner. Crucially, in this same step, the expanding EPS foam bonds directly to the inside of the polycarbonate shell, creating a single, integrated piece. This fusion makes the entire bike helmet structure stronger and allows for the design of larger, more effective vents without compromising safety. At SPIRIT, we have perfected this in-mold process over nearly two decades, ensuring a flawless bond and structural integrity in every bike helmet we produce.

Customizing a bike helmet is what transforms a great product into your great product. At SPIRIT, we provide a comprehensive suite of customization options to bring your brand identity to life. The process begins with color. Our clients can specify any color using the Pantone Matching System to ensure perfect brand consistency. Next is the finish; we can produce a helmet in a high-gloss, sleek matte, or a combination of both for a premium look. Graphic application is a critical step, where we employ techniques like high-quality water slide decals for intricate, detailed logos and heat transfer for durable, full-coverage graphics. But customization doesn't stop at the shell. We offer custom-colored straps, unique buckle mechanisms, and branded retention system dials. Even the internal padding can be customized for color and comfort. The entire design and development process for a custom bike helmet at SPIRIT is a collaborative journey to ensure every detail reflects your brand's unique vision and quality standards.