This is how a new bicycle helmet is created – from the idea to the finished product

How is a bicycle helmet actually made? What are the materials and how are the models designed? Good questions! We want to bring you closer to KED's processes and give you a little look behind the scenes. The development of a new helmet is an exciting process that involves many steps. At KED this means that we take a structured and creative approach from the initial idea to the finished product. The focus is always on safety, quality and the needs of our customers. Let's take a look at KED production together.

Ideation

The journey begins with ideation. Various aspects come together here: Customer feedback, Market trends and innovative concepts. Through our direct contact with customers - be it through factory outlets or at trade fairs - we collect valuable suggestions and requests that help us develop helmets that are both safe and aesthetically pleasing.

Market research and customer needs

Okay, the first ideas have been collected – what now? At KED, we attach great importance to market research in order to precisely understand the needs of our customers. Workshops with sales representatives and regular surveys provide us with essential information that flows into product development. This means our products always remain up to date and can meet all important requirements. 

Innovation processes and brainstorming

In creative brainstorming sessions, we work with our team to develop innovative ideas and try to integrate and implement all the information, technologies and requirements that we have developed in the previous steps. Technical possibilities and trends are also taken into account to ensure that our helmets are not only functional, but also future-oriented. 

Design phase

Once we have a clear vision, the design phase begins. Here our designers sketch initial drafts and create prototypes. These prototypes will be further refined in the testing phase.

Sketching and prototyping

The first sketches turn into digital designs, which are then implemented into prototypes. During this process we select materials that are both high quality and sustainable.

When selecting materials, we attach great importance to safety and quality. Innovative technologies help us make the helmets light and comfortable. The longevity and recyclability of the materials are important to us, which is why we only use high-quality raw materials meet strict safety standards.

Test phase

Now we're entering the testing phase! This step is crucial – because this is where the prototypes are put through their paces. Safety testing and quality controls are essential. Here we also start producing the tools – EPS Foaming tool, deep-drawing tool, milling holders, and others. Typically, this entire process takes eight to ten weeks. During this time, we will carry out further tests with the prototypes and obtain feedback from customers. 

Safety testing and quality control

As soon as the first prototypes with the finished tools are ready, we test them again. The necessary security tests are carried out. Only if the helmet meets the requirements and passes the certification test can the helmet go into series production. 

Final feedback from test subjects

In addition, we collect feedback from test subjects to ensure that our helmets meet user expectations. This feedback is incorporated into the final design adjustments before series production.

production

The production of our helmets takes place in several steps. We work closely with our suppliers to get the best materials at the right time. Production methods vary depending on the type of helmet.

We use two main methods: the traditional method where the peel is placed on the EPS is glued, and the modern In-Mold-Production, in the shell and EPS be foamed together. The individual production stations include pressure, Deep drawing, Milling, Foaming, Pre-assembly and Final assembly.

Market launch

Last but not least – after production comes the market launch. Here it is important to collect customer feedback and make small adjustments if necessary. Color changes and minor modifications are possible in this step.

Challenges 

One of the biggest challenges in production at KED is combining the highest quality standards with efficient work. Especially at the In-Mold-Production, the combination of precision and speed is crucial. The most modern machines and well-trained staff are used here. Our location in Germany offers us the advantage of being able to react flexibly to customer requests and produce in a targeted manner instead of producing large quantities in stock. 

However, this flexibility requires precise planning and coordination in order to balance our customers' changing requirements with a smooth production process. In addition, the continuous testing of new, sustainable materials is a challenge that we take seriously. We must ensure that these tests are carried out thoroughly without disrupting regular production flow. The balance between innovation, sustainability and efficiency therefore remains a constant task to which we dedicate ourselves with great commitment.

Conclusion – this is how your KED helmet is created! 

The path from the idea to the finished helmet is a dynamic process that requires creativity, precision and customer focus. At KED, we pride ourselves on developing innovative and safe products that not only offer protection, but are also fun to wear. With every new helmet we continue our passion for quality and safety and are happy that you are part of KED Community you are! So, Which helmet is your absolute favorite??