INTEGRATED MANUFACTURING PROCESS

INTEGRATED MANUFACTURING PROCESS

All of the stages of the production cycle are managed from within the company: from the receiving of the raw materials to the final assembly of the product. This ensures the constant evolution of production technology and the maintaining of the highest standards in quality. Below, the main stages: the moulding and finishing of the outer shell, the moulding of the inner components in polystyrene, the moulding of the visor/VPS sunscreen and scratch resistant/fog resistant treatment, the cut and siliconizing of the fog resistant inner visor, the moulding of various complementary plastic components (air intakes, visor mechanisms ...), the painting of the outer shell and application of graphics, the cutting and preparation of the inner comfort padding, the final assembly of the product.



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The production of the outer shell for Nolan and Grex brand helmets occurs trough LEXANTM* polycarbonate injection moulding process. LEXANTM* is a material ensuring, for the same shape, thickness and process, higher performance compared to ABS, the raw material used for the moulding of almost all motorbike helmets on the market. The polycarbonate provides superior performance in both mechanical and thermal terms: during impact resistance tests, the polycarbonate obtained results of 900/1000 J/m, compared to the maximum results of 550/600 J/m for ABS. Furthermore, the thermal range of the polycarbonate is between -30°C to +120°C compared to a range of -20°C to +50°C for ABS. At 80°C (the temperature that the helmet may be required to endu- re in the summer, closed in a pannier), the polycarbonate remains stable, while ABS undergoes deformation; at 100°C, LEXANTM* still maintains its dimensional stability, while ABS deforms completely. The same test carried out at -20°C shows how LEXANTM* does not suffer cracks at harsh tempe- ratures, while ABS becomes very fragile.



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The polycarbonate provides superior performance in both mechani- cal and thermal terms: during impact resistance tests, the polycarbonate obtained results of 900/1000 J/m, compared to the maximum results of 550/600 J/m for ABS. Furthermore, the thermal range of the polycarbonate is between -30°C to +120°C compared to a range of -20°C to +50°C for ABS. At 80°C (the temperature that the helmet may be required to endu- re in the summer, closed in a pannier), the polycarbonate remains stable, while ABS undergoes deformation; at 100°C, LEXANTM* still maintains its dimensional stability, while ABS deforms completely. The same test carried out at -20°C shows how LEXANTM* does not suffer cracks at harsh tempe- ratures, while ABS becomes very fragile.

The production of the outer shell for X-lite helmets is based on the use of multi-axial hybrid fabrics (carbon-glass and aramid-glass) which are cut, in order to produce over 100 reinforcement pieces forming the base of the layers of the shell. Pre-established “recipes” differing in relation to the homologation required, the model and the size of the product. During the moulding phase of the shell, a thermosetting resin is poured into the layered mould and, via pressure from a counter-mould, is hardened, absorbing and binding the fabrics. A numerically-controlled water jet machine cuts the shell: at high pressure, approximately 4,000 bar, visor windows and air intakes are cut.The cycle ends with the automatic sanding of the shell by robot, visual checks and manual finishing for painting.



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