A Strong Partnership for the Highest Standards in Helmet Systems: Schuberth and RUCH NOVAPLAST

Schuberth is one of the world’s leading manufacturers of high-quality helmet systems. The company develops solutions for a wide range of applications, from motorsports and motorcycle helmets to military applications. Its focus is on the highest safety standards, innovative technologies, and maximum quality. The strong partnership between Schuberth and RUCH NOVAPLAST helps ensure that these high standards are met.

The development of modern helmet systems requires a deep understanding of materials, component design, and manufacturing processes. Depending on the application and function within the helmet, different particle foams, design concepts, and technical solutions are used.

Long-standing partnership in the development of helmet systems

RUCH NOVAPLAST and Schuberth have enjoyed a close and successful partnership for 25 years. The partnership began with the production of helmet shells for Formula 1 and has continued to evolve ever since. Today, the collaboration goes far beyond a traditional supplier relationship: Both companies are committed to joint development, combining technical expertise, experience, and innovative strength.

Maximum safety with low weight

In joint projects, demanding and sometimes conflicting requirements often come into play. These include outstanding crash performance combined with the thinnest possible wall thickness, as well as low overall weight with maximum stability of the lightweight material used. Depending on the application—whether Formula 1, motorcycles, law enforcement, or the military—the requirements for open-cell foam vary significantly. In the military sector, for example, the focus is on rigid and durable structures for ballistic protection that can simultaneously absorb impact energy through controlled deformation. In motorsports, particularly in Formula 1, helmets must offer maximum protection while weighing as little as possible and must function reliably even under high mechanical and thermal stresses.

Multi-piece EPS inner shells for optimal energy absorption

To meet these requirements, the choice of materials and the design of the helmet’s inner shell play a crucial role. Expanded polystyrene (EPS) is used for the inner shells, as this material combines very low weight with excellent shock-absorbing properties. In the event of an impact, the EPS deforms in a controlled manner, absorbing a large portion of the resulting energy. This significantly reduces the forces acting on the head.

The highly functional EPS inner shell features a multi-part structure in which molded components of varying densities are strategically combined. This allows the shock-absorbing properties to be optimally tailored to various types of impact and enables the forces generated during an impact to be specifically absorbed and distributed. This enhances the helmet’s protective effect and plays a key role in ensuring the highest level of safety for the wearer.

Functionalization Through Integrated Fasteners

In addition to the material properties of the inner shell, the integration of additional functions also plays an important role. RUCH NOVAPLAST uses inserts—that is, integrated fasteners—to add functionality. These are connected to the inner shell via a form-fit, thereby ensuring exceptionally high stability and quality of the components. They serve as robust mounting points for upholstery elements. At the same time, they enable the direct integration of additional functions, thereby optimizing assembly steps and improving overall quality. However, the end user is always the focus of collaborative product development. Ultimately, it is the end user who benefits most from the numerous innovations—both large and small, visible and invisible—as they make the product easier to use while also helping to enhance both active and passive safety.

Optimized airflow through molded particle foam components

In addition, targeted airflow within the helmets plays an important role. It contributes significantly to achieving an optimal balance between comfort and functionality. Thanks to the three-dimensional moldability of particle foam components, precise air channels can be integrated directly into the helmet shell. These channels ensure improved ventilation and aid in heat dissipation, thereby guaranteeing a comfortable wearing experience. As a lightweight material, particle foam thus contributes not only to safety but also to the comfort and functionality of modern helmet systems. However, particle foam is not only used in the inner shell of modern helmet systems.

Durable EPP chin pads

The chin pads are also made of particle foam. Unlike the helmet liner, the chin pads are made of expanded polypropylene (EPP). Compared to EPS, this material is characterized by exceptionally high resilience and is therefore ideal for components that are repeatedly exposed to mechanical stress. At the same time, EPP combines low weight with high energy absorption, thereby contributing to the helmet’s safety and comfort. To achieve a durable, high-quality surface, the chin pads are additionally covered with a protective layer. This creates a seamless, abrasion-resistant outer layer while preserving the beneficial properties of the cellular foam.

RUCH NOVAPLAST also applies the experience gained from these projects in the development of complex molded parts to other applications involving particle foam. In particular, the design and manufacture of sophisticated EPP molded parts require a deep understanding of material behavior, component design, and process control—knowledge that is also incorporated into the development of modern helmet systems and EPS inner shells.