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Ensolite is an energy absorbing foam originally developed by NASA to protect pressure vessels from damage. It has virtually 100% memory and is waterproof.

Composite Craft has taken their carb31 fiber helmet to the next level of safety. For added protection and comfort, the Polo style, Extended 1/2 Shell, and Head Trip Helmets now come with the new "Ensolite" energy absorbing foam liner.

This foam is much more impact resistant compared to the common foam liners used in most helmets.If necessary, the removable cushioned sizing pads can be cut for a custom fit or removed altogether.

All helmets are basically made the same way, a female mold is gel-coated with either a clear or colored gel-coat then fibers are layed into the female mold, resin is applied and the material rolled out to remove as much air as possible. The part is then left to cure at either room temperature or it's heated to accelerate the cure. Although this is a good way to make a lot of helmets pretty quickly it does not result in a shell that offers much in the way of structural integrity compared to a high-pressure laminate. This is where Composite Craft differs from the rest.

When talking about laminate structure and materials related to non-pressure versus high pressure laminating, the difference is that using high pressure versus no pressure controls the laminate and its compaction. Compacting the fiber and injecting exactly the right amount of resin results in a shell that far exceeds the shell produced with no pressure. And having exactly the right amount of resin versus fiber controls laminate structure. This is called fiber volume. In the very best wet lay-up hand laminated helmet the best resin content versus fiber volume is 50%. This means there are 50% resin and 50% fiber. Resin really has no strength in comparison to the fiber. So you need to control the resin content to a minimum versus fiber. Basically the resin is there to keep the fibers in place

Composite Craft uses a modified resin transfer system, this process involves basically the same process as the non-pressure laminate, a female mold is sprayed with gel coat, Multiple layers of fiber are put in the mold but then pressure is applied at 75psi inside the mold. Resin is then injected in exactly the right amount and the helmet is heated to cure. By injecting the resin we can achieve a 40% resin to 60% Fiber ratio, which is optimum for helmet shells. The result is a laminate that yields all the structural integrity that the materials were meant to have.

Now that you know about the process you may be asking what's the difference between Fiberglass, Carbon Fiber and Kevlar. Everyone knows basically what fiberglass is, extruded glass. 95% of all helmets are made from fiberglass be it mat (random fibers) or woven fabric. They are all basically the same. One key factor is fiberglass is cheap.

Carbon fiber is made by superheating an acrylic fiber yielding high strength to weight and high stiffness to weight properties. When engineered properly Carbon Fiber composites can achieve the strength and stiffness of metals at a significant weight savings, these two factors are key to the manufacture of a helmet.

Kevlar is made by dissolving a polymer in a solvent and extruding the fiber and then spinning. While Kevlar has properties similar to Carbon Fiber it lacks compressive strength. The combination of 50% Carbon Fiber and 50% Kevlar results in a laminate with flexural strength about three times that of Kevlar alone.

Below is a comparison of typical fiber properties of some of the materials we use.

By using Carbon/Kevlar and our high pressure laminating process we can produce a helmet shell with far superior strength to weight ratio. The stiffness (42.3 MSI) of Carbon Fiber being a contributing factor to that strength and weight based on its density (1.78(g/cc)

Most helmets have a very cheap headliner material for the liner. We use an energy absorbing foam called Ensolite for our liner, while still being comfortable it offers energy absorbing properties that headliner material does not. Resulting in a small but safe helmet.

Composite Craft is a Custom Helmet Manufacturer. We build each helmet by hand - one at a time. No compromise is ever made in the quality of the helmet.