Wholesale Adult Mountain Bicycle Safety Helmet

This helmet is designed for adult riders who require impact protection on off‑road terrain. The geometry follows a full‑coverage shape that extends over the occipital region and temples, reducing the likelihood of direct contact with rocks, roots or branches.

Key Design Specifications

The outer shell is manufactured from injection‑molded polycarbonate with a nominal thickness of 2.0 mm, providing a balance between stiffness and weight. The impact‑absorbing liner consists of expanded polystyrene (EPS) beads with a density range of 20–25 kg/m³, tuned to absorb kinetic energy according to the linear impact velocity of 6.2 m/s.

Ventilation is achieved through 12 rectangular openings, each 18 mm × 8 mm, positioned to create a front‑to‑rear airflow path. The retention system uses a micro‑adjustable dial with a 360° range, allowing a head circumference adjustment from 54 cm to 62 cm without tools.

Impact Performance and Standards

The helmet is tested to meet the CPSC 1203 bicycle helmet standard and the European EN 1078:2012+A1:2012 specification. In the vertical drop test, a 5 kg striker impacts the helmet at 2 m/s, resulting in a peak acceleration below 250 g, which satisfies the injury‑risk threshold for traumatic brain injury.

Energy absorption is measured using a force‑deflection curve; the liner compresses approximately 12 mm under the test load, dissipating roughly 45 J of energy. These values are typical for a helmet of this size and liner density, and can be verified per batch upon request.

Typical Technical Parameters

Manufacturing Considerations for Bulk Orders

Tooling for the polycarbonate shell is designed for high‑cavitation molds, enabling cycle times of approximately 45 seconds per part at 260 °C barrel temperature. The EPS liner is produced via bead expansion in a closed‑mold process, allowing density tolerance of ± 2 kg/m³. Both operations are compatible with continuous feed systems, supporting lot sizes of 5 000 units or more without changeover.

Secondary operations include pad printing for logos and UV‑clear coating for scratch resistance. The coating adds roughly 5 µm thickness and does not affect impact performance, as verified by retained acceleration values within 5 % of baseline.

Applications in Wholesale Distribution

Wholesale buyers benefit from a standardized SKU that fits the majority of adult mountain‑bike riders, reducing the need for multiple size variants. The helmet’s stackable packaging—designed with interlocking corrugated trays—allows 48 units per master carton, optimizing pallet utilization and lowering freight cost per unit.

Because the retention system adjusts without tools, end‑users can achieve a secure fit quickly, which lowers return rates related to sizing issues. This characteristic is particularly valuable for distributors serving retail chains that require ready‑to‑shelf merchandise.

Customization Options

• Logo placement: front, sides, or rear via pad printing or hydro‑graphics
• Color matching: Pantone or RAL codes available for shell and liner
• Visor integration: detachable polycarbonate visor with 2‑mm thickness
• Reflective strips: 3M Scotchlite tape applied to rear vents

Quality Control Process

Each production lot undergoes incoming material verification: PC melt flow index (MFI) tested at 260 °C/5 kg, EPS bead density measured by gravimetric method. In‑process checks include dimensional inspection of shell thickness using ultrasonic gauging (± 0.1 mm tolerance) and liner compression set after 24 h at 23 °C/50 % RH.

Finished‑good inspection consists of random sampling per ANSI/ASQ Z1.4 (level II). Samples are subjected to the standard impact drop test; any lot exceeding a failure rate of 0.5 % is quarantined for root‑cause analysis. Documentation of test results is retained for three years and made available to buyers upon request.

Inspection Checklist

For wholesale pricing, lead times, or to request a sample kit, please reach out to our sales team.